Fire barrier layer and fire barrier film laminate

ABSTRACT

A fire barrier laminate is provided for use in thermal and acoustical insulation systems, such as, but not limited to, those used in commercial aircraft.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation application of co-pending U.S.Ser. No. 13/802,537 filed on Mar. 13, 2013, which is acontinuation-in-part of U.S. Ser. No. 13/299,399 filed on Nov. 18, 2011,and which claims priority to U.S. Provisional Application Nos.61/616,323 filed on Mar. 27, 2012, and 61/415,552 filed on Nov. 19,2010. The present application is also a continuation-in-part applicationof co-pending U.S. Ser. No. 13/299,399 filed on Nov. 18, 2011, whichclaims priority to U.S. Provisional Application No. 61/415,552 filed onNov. 19, 2010.

TECHNICAL FIELD

A fire barrier laminate is provided for use in thermal and acousticalinsulation systems, such as, but not limited to, those used incommercial aircraft.

BACKGROUND

The Federal Aviation Administration (FAA) has promulgated regulations,contained in 14 C.F.R. §§ 25.856(a) and (b), requiring thermal andacoustical insulation blanket systems in commercial aircraft to provideimproved burn through protection and flame propagation resistance. Theseconventional thermal and acoustical insulation systems typically includethermal and acoustical insulation blankets encapsulated within a filmcovering or bag. As the thermal and acoustical insulation systems areconventionally constructed, the burn through regulations primarilyaffect the contents of the insulation systems' bags and the flamepropagation resistance regulations primarily affect the film coveringsused to fabricate the bags. Conventional film coverings typically areused as a layer or covering, for example, laid over or laid behindlayers of thermal and acoustical insulation material, or as a coveringor bag for partially or totally encapsulating one or more layers ofthermal and acoustical insulation material.

The materials utilized in existing fire barrier materials may have poorthermal conductivity, may absorb moisture, and may tend to be fragileduring handling or in use where harsh mechanical environments areencountered.

In certain embodiments, a fire barrier layer comprising an inorganicpigment that can be incorporated into a subject fire barrier laminateused for protecting thermal and acoustical insulation structures isprovided. In certain embodiments, the present fire barrier laminate hasimproved mechanical stability, increased thermal conductivity anddecreased water absorption.

SUMMARY

In one embodiment, the present fire barrier laminate includes a firebarrier layer which is incorporated into the fire barrier laminate foruse in thermal and acoustical insulation systems, such as, but notlimited to, those used in commercial aircraft. By way of example, butnot limitation, the fire barrier laminate may be used as a covering thatis located between insulation material in fuselage wall cavities and theouter skin of an aircraft fuselage (as an outboard cover of aninsulation system) and/or between insulation material in fuselage wallcavities and the interior aircraft trim panels (as an inboard cover ofan insulation system).

In certain embodiments, the subject fire barrier film laminate comprisesat least one non-fibrous fire barrier layer coated onto at least onefilm layer, optionally a water-repellant material incorporated intoand/or applied to the fire barrier layer, optionally at least one scrimlayer, at least one second film layer, and optionally at least oneadhesive layer, the non-fibrous fire barrier layer comprising at leastone inorganic platelet material, optionally at least one organic binderand/or inorganic binder, and optionally at least one functional filler.

In one embodiment, the subject fire barrier film comprises at least onenon-fibrous fire barrier layer coated onto at least one film layer, awater-repellant material incorporated into and/or applied to the firebarrier layer, at least one scrim layer, at least one secondary filmlayer, and optionally at least one adhesive layer, the non-fibrous firebarrier layer comprising at least one inorganic platelet material,optionally at least one organic binder and/or inorganic binder. In oneembodiment, the non-fibrous fire barrier layer comprises at least oneinorganic pigment material. In one embodiment, the at least oneinorganic pigment material is a metal oxide-coated inorganic plateletmaterial. In one embodiment, the metal oxide-coated inorganic plateletmaterial is metal oxide-coated mica platelets.

In one embodiment, the subject fire barrier film laminate comprises:

-   -   a. a first film layer;    -   b. a support layer on top of the first film layer;    -   c. a non-fibrous fire barrier layer on top of the support layer;        and    -   d. optionally, a second film layer on top of the non-fibrous        fire barrier layer.

In one embodiment, the support layer comprises a fibrous layer and anadhesive.

In one embodiment, the support layer comprises a fibrous layer.

In one embodiment, the first film layer is on top of a scrim. In analternate embodiment, the scrim is on top of the first film layer.

In one embodiment, the non-fibrous fire barrier layer comprises at leastone inorganic pigment material.

In one embodiment, the at least one inorganic pigment material is ametal oxide-coated inorganic platelet material. In one embodiment, themetal oxide-coated inorganic platelet material is metal oxide-coatedmica platelets.

In one embodiment, there is an adhesive layer between the non-fibrousfire barrier layer and the second film layer.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form partof the specification, illustrate various embodiments of the present firebarrier laminate and, together with the description, further serve toexplain the principles of the fire barrier laminate and to enable aperson of ordinary skill in the art to make and use the fire barrierlaminate. In the drawings, like reference numbers indicate identical orfunctionally similar elements. A more complete appreciation of the firebarrier laminate and many of the attendant advantages thereof will bereadily obtained as the same becomes better understood by reference tothe following detailed description when considered in connection withthe accompanying drawings, wherein:

FIG. 1A is a schematic cross-sectional view of a thermal and acousticalaircraft insulation blanket protected by an embodiment of the subjectfire barrier laminate.

FIG. 1B is an exploded cross-sectional view of the subject fire barrierlaminate circled portion B′ of the embodiment of FIG. 1A.

FIG. 1C is an exploded cross-sectional view of another illustrativeembodiment of the subject fire barrier laminate circled portion B′ ofthe embodiment of FIG. 1A.

FIG. 1D is an exploded cross-sectional view of a further illustrativeembodiment of the subject fire barrier laminate circled portion B′ ofthe embodiment of FIG. 1A.

FIG. 1E is an exploded cross-sectional view of a further illustrativeembodiment of the subject fire barrier laminate circled portion B′ ofthe embodiment of FIG. 1A.

FIG. 2 depicts a further illustrative embodiment of the subject firebarrier laminate. Panel a) depicts a fire barrier laminate comprising afirst film layer (500), with a support layer (501) coated onto the topsurface of the first film layer (500). The support layer (501) comprisesa fibrous layer (502) in a first adhesive layer (503). A non-fibrousfire barrier layer (504) is coated onto the support layer (501). Asecond adhesive layer (505) is coated onto the non-fibrous fire barrierlayer (504), onto which a second film layer (506) is overlaid. Panel b)depicts a fire barrier laminate comprising a scrim (507) that islaminated to the bottom surface of the first film layer (500) using aheat seal adhesive (508). The first film layer (500) has a support layer(501) coated onto the top surface of the first film layer (500). Thesupport layer (501) comprises a fibrous layer (502) in a first adhesivelayer (503). A non-fibrous fire barrier layer (504) is coated onto thesupport layer (501). A second adhesive layer (505) is coated onto thenon-fibrous fire barrier layer (504), onto which a second film layer(506) is overlaid.

FIG. 3 depicts a further illustrative embodiment of the subject firebarrier laminate. Panel a) depicts a fire barrier laminate comprising afirst film layer (500), with a support layer (501) coated onto the topsurface of the first film layer (500). The support layer (501) comprisesa fibrous layer (502) in a first adhesive (503). A non-fibrous firebarrier layer (504) is coated onto the support layer (501). A secondsupport layer (509) is coated on to the non-fibrous fire barrier layer(504). The second support layer (509) comprises a glass fabric (502) anda first adhesive layer (503). A second adhesive layer (505) is coatedonto the second support layer (509), onto which a second film layer(506) is overlaid. Panel b) depicts a fire barrier laminate comprising ascrim (507) that is laminated to the bottom surface of the first filmlayer (500) using a heat seal adhesive (508). The first film layer (500)has a support layer (501) coated onto the top surface of the first filmlayer (500). The support layer (501) comprises a fibrous layer (502) ina first adhesive layer (503). A non-fibrous fire barrier layer (504) iscoated onto the support layer (501). A second support layer (509) iscoated on to the non-fibrous fire barrier layer (504). The secondsupport layer (509) comprises a glass fabric (502) and a first adhesive(503). A second adhesive layer (505) is coated onto the second supportlayer (509), onto which a second film layer (506) is overlaid.

FIG. 4 depicts a further illustrative embodiment of the subject firebarrier laminate. Panel a) depicts a fire barrier laminate comprising afirst film layer (500) onto which a fibrous layer (502) is overlaid. Anon-fibrous fire barrier layer (504) is coated onto the fibrous layer(502). A third adhesive layer (510) is coated onto the non-fibrous firebarrier layer (504), onto which a second film layer (506) is overlaid.Panel b) depicts a fire barrier laminate comprising a scrim (507) thatis laminated to the bottom surface of the first film layer (500) using aheat seal adhesive (508). A fibrous layer (502) is overlaid on to thetop surface of the first film layer (500). A non-fibrous fire barrierlayer (504) is coated onto the fibrous layer (502). A third adhesivelayer (510) is coated onto the non-fibrous fire barrier layer (504),onto which a second film layer (506) is overlaid.

FIG. 5 depicts a further illustrative embodiment of the subject firebarrier laminate. Panel a) depicts a fire barrier laminate comprising afirst film layer (500) onto which a fibrous layer (502) is overlaid. Anon-fibrous fire barrier layer (504) is coated onto the fibrous layer(502). A second film layer (506) is overlaid on to the non-fibrous firebarrier layer (504). Panel b) depicts a fire barrier laminate comprisinga scrim (507) that is laminated to the bottom surface of the first filmlayer (500) using a heat seal adhesive (508). A fibrous layer (502) isoverlaid on to the top surface of the first film layer (500). Anon-fibrous fire barrier layer (504) is coated onto the fibrous layer(502). A second film layer (506) is overlaid on to the non-fibrous firebarrier layer (504).

FIG. 6 depicts a further illustrative embodiment of the subject firebarrier laminate. Panel a) depicts a fire barrier laminate comprising afirst film layer (500) coated with a first adhesive (503), onto which afibrous layer (502) is overlaid. A non-fibrous fire barrier layer (504)is coated onto the fibrous layer (502). A second adhesive layer (505) iscoated onto the non-fibrous fire barrier layer (504), onto which asecond film layer (506) is overlaid. Panel b) depicts a fire barrierlaminate comprising a scrim (507) that is laminated to the bottomsurface of the first film layer (500) using a heat seal adhesive (508).The top surface of the first film layer is coated with a first adhesive(503), onto which a fibrous layer (502) is overlaid. A non-fibrous firebarrier layer (504) is coated onto the fibrous layer (502). A secondadhesive layer (505) is coated onto the non-fibrous fire barrier layer(504), onto which a second film layer (506) is overlaid.

FIG. 7 depicts a further illustrative embodiment of the subject firebarrier laminate. Panel a) depicts a fire barrier laminate comprising afirst film layer (500) coated with a first adhesive layer (503), ontowhich a fibrous layer (502) is overlaid. A non-fibrous fire barrierlayer (504) is coated onto the fibrous layer (502), onto which a secondfilm layer (506) is overlaid. Panel b) depicts a fire barrier laminatecomprising a scrim (507) that is laminated to the bottom surface of thefirst film layer (500) using a heat seal adhesive (508). The top surfaceof the first film layer is coated with a first adhesive (503), ontowhich a fibrous layer (502) is overlaid. A non-fibrous fire barrierlayer (504) is coated onto the fibrous layer (502), onto which a secondfilm layer (506) is overlaid.

DETAILED DESCRIPTION

For clarity of disclosure, and not by way of limitation, the detaileddescription is divided into the following subsections that describe orillustrate certain features, embodiments or applications of the presentfire barrier laminate.

Non-Fibrous Fire Barrier Layer Comprising Inorganic Platelet Material

In certain embodiments, the subject fire barrier film laminate comprisesat least one non-fibrous fire barrier layer coated onto at least onefilm layer, optionally a water-repellant material incorporated intoand/or applied to the fire barrier layer, at least one scrim layer, atleast one second film layer, and optionally at least one adhesive layer,the non-fibrous fire barrier layer comprising at least one inorganicplatelet material, optionally at least one organic binder and/orinorganic binder, and optionally at least one functional filler.

Without wishing to be limited by theory, in fire barriers utilizingplain or uncoated mica based platelet materials, the individualplatelets may be held together by Van der Waals forces. The Van derWaals forces may be reinforced by the addition of a resin or adhesivethat provides covalent bonds between the platelets and the resin oradhesive.

In certain embodiments, the fire barrier laminate comprises: at leastone non-fibrous fire barrier layer directly or indirectly coated onto atleast one first polymeric flame propagation resistant film layer; atleast one second film layer proximate to the non-fibrous fire barrierlayer opposite the first polymeric flame propagation resistant filmlayer; at least one scrim layer disposed: (i) between the non-fibrousfire barrier layer and the first polymeric flame propagation resistantfilm layer; and/or (ii) between the non-fibrous fire barrier layer andthe second film layer; and/or (iii) proximate to the first polymericflame propagation resistant film layer opposite the non-fibrous firebarrier layer; and/or (iv) proximate to the second film layer oppositethe non-fibrous fire barrier layer; optionally, a water-repellantmaterial incorporated into and/or applied to the non-fibrous firebarrier layer; optionally at least one adhesive layer adhering thenon-fibrous fire barrier layer to the first polymeric flame propagationresistant film layer; and optionally at least one adhesive layeradhering the scrim layer to at least one of the non-fibrous fire barrierlayer, the first polymeric flame propagation resistant film layer, orthe second film layer; wherein the non-fibrous fire barrier layercomprises at least one inorganic platelet material, optionally at leastone organic binder and/or inorganic binder, and optionally at least onefunctional filler. Optionally, the second film layer may also be flamepropagation resistant.

By indirectly coating, it is meant that the non-fibrous fire barrierlayer may be coated onto an intermediate layer, such as a scrim, whereinthe intermediate layer is engaged with the first polymeric flamepropagation resistant film layer. The intermediate layer may be engagedwith the first polymeric flame propagation resistant film layer beforeor after being coated with the non-fibrous fire barrier layer.

This composition provides a light basis weight article with surprisingresistance to damage associated with handling and use along with theability to resist flame propagation and flame penetration as defined in14 C.F.R. §§ 25.856 (a) and (b). The term “basis weight” is defined asthe weight per unit area, typically defined in grams per square meter(gsm). The subject fire barrier layer, and the laminate incorporatingit, are therefore useful in providing fire burn-through protection forthermal and acoustical insulation structures, referred to in theindustry as “blankets”, for commercial aircraft fuselages, as thesubject fire barrier laminate may have a basis weight of between about80 gsm to about 120 gsm, and in certain embodiments between about 90 gsmto about 110 gsm.

The inorganic platelet material of the fire barrier layer may compriseat least one of vermiculite, mica, clay or talc. While any sizeinorganic platelet material may be used, inorganic platelet materialswith larger relative diameters and high diameter to thickness aspectratios may be desirable due to their increased flame propagation and/orburnthrough resistance performance, as well as other properties such asflexibility and processibility. In certain embodiments, the inorganicplatelet material may have a diameter of from about 20 μm to about 300μm. In further embodiments, the inorganic platelet material may have adiameter of from about 40 μm to about 200 μm. In certain embodiments,the inorganic platelet material may have an aspect ratio of from about50:1 to about 2000:1. In certain embodiments, the inorganic plateletmaterial may have an aspect ratio of from about 50:1 to about 1000:1. Infurther embodiments, the inorganic platelet material may have an aspectratio of from about 200:1 to about 800:1.

The vermiculite may be exfoliated, and may further be defoliated. Byexfoliation, it is meant that the vermiculite is chemically or thermallyexpanded. By defoliated, it is meant that the exfoliated vermiculite isprocessed in order to reduce the vermiculite to substantially a plateletform. Vermiculite may be included in the fire barrier layer in an amountfrom about 20 to about 100 weight percent, based on the total weight ofthe fire barrier layer.

Suitable micas may include, without limitation, muscovite, phlogopite,biotite, lepidolite, glauconite, paragonite and zinnwaldite, and mayinclude synthetic micas such as fluorophlogopite. Mica may be includedin the fire barrier layer in an amount from about 20 to about 100 weightpercent, based on the total weight of the fire barrier layer.

Suitable platelet clay materials that may be included in the firebarrier layer include, without limitation, ball clay, bentonite,smectite, hectorite, kaolinite, montmorillonite, saponite, sepiolite,sauconite, or combinations thereof. Platelet clay materials may beincluded in the fire barrier layer in an amount from about 5 to about 60weight percent, in certain embodiments from about 5 to about 50 weightpercent, based on the total weight of the fire barrier layer.

The mica, vermiculite and/or clay platelet materials may also becombined with further platelet materials, such as talc. If present, talcmay be included in the fire barrier layer in an amount from about 1 toabout 50 weight percent, in certain embodiments, from about 10 to about30 weight percent, based on the total weight of the fire barrier layer.

The fire barrier layer may include inorganic binders. Withoutlimitation, suitable inorganic binders include colloidal dispersions ofalumina, silica, zirconia, and mixtures thereof. The inorganic binders,if present, may be used in amounts ranging from 0 to about 40 percent byweight, in some embodiments from 0 to about 20 weight percent, basedupon the total weight of the fire barrier layer.

The fire barrier layer may further include one or more organic binders.The organic binder(s) may be provided as a solid, a liquid, a solution,a dispersion, a latex, or similar form. Examples of suitable organicbinders include, but are not limited to, acrylic latex, (meth)acryliclatex, phenolic resins, copolymers of styrene and butadiene,vinylpyridine, acrylonitrile, copolymers of acrylonitrile and styrene,vinyl chloride, polyurethane, copolymers of vinyl acetate and ethylene,polyamides, silicones, unsaturated polyesters, epoxy resins, polyvinylesters (such as polyvinylacetate or polyvinylbutyrate latexes) and thelike.

The organic binder, if present, may be included in the fire barrierlayer in an amount of from 0 to about 40 weight percent, in someembodiments from 0 to about 20 weight percent, based upon the totalweight of the fire barrier layer.

Solvents for the binders, if needed, can include water or a suitableorganic solvent, such as acetone, for the binder utilized. Solutionstrength of the binder in the solvent (if used) can be determined byconventional methods based on the binder loading desired and theworkability of the binder system (viscosity, solids content, etc.).

In certain embodiments, the fire barrier layer may comprise from about20% to about 100% by weight of the inorganic platelet material, from 0%to about 40% by weight of the organic binder and/or inorganic binder,and from 0% to about 50% of the functional filler.

In further embodiments, the fire barrier layer may comprise from about60% to about 100% by weight of the inorganic platelet material, from 0%to about 20% by weight of the organic binder and/or inorganic binder,and from 0% to about 20% of the functional filler.

The fire barrier film laminate and/or the fire barrier layer mayadditionally comprise a water repellant additive or coating. The waterrepellant additive or coating may be a component of the fire barrierlayer or may be a distinct coating or layer within the fire barrier filmlaminate, or may be saturated or impregnated into the fire barrierlayer. The water repellant additive may alternatively or additionally bepresent in the adhesives, which may be utilized in the subject firebarrier laminate. Without limitation, the water repellant additive orcoating may comprise a water repellant silicone; a metal chloride saltsuch as calcium chloride, magnesium chloride, sodium chloride, potassiumchloride, or aluminum chloride; silane; fluorinated compounds orfluorosurfactants such as polytetrafluoroethylene resin; polymeric wetstrength resins such as polyamide resin or polyamide-epichlorohydrinresin; mixtures thereof, and the like.

The functional filler(s) may include, but not be limited to,non-platelet clays (such as attapulgite, kyanite, palygorskite,silimanite, or andalucite), fumed silica, boron nitride, cordierite andthe like. According to certain embodiments, the functional fillers mayinclude finely divided metal oxides, which may comprise at least one ofpyrogenic silicas, arc silicas, low-alkali precipitated silicas, fumedsilica, silicon dioxide aerogels, aluminum oxides, titania, calcia,magnesia, potassia, and mixtures thereof.

In certain embodiments, the functional filler may comprise endothermicfillers such as alumina trihydrate, magnesium carbonate, and otherhydrated inorganic materials including cements, hydrated zinc borate,calcium sulfate (gypsum), magnesium ammonium phosphate, magnesiumhydroxide and combinations thereof. In further embodiments, thefunctional filler(s) may include lithium-containing minerals. In stillfurther embodiments, the functional fillers(s) may include fluxingagents and/or fusing agents.

In certain embodiments, the functional filler may comprise fireretardant fillers such as antimony compounds, magnesium hydroxide,hydrated alumina compounds, borates, carbonates, bicarbonates, inorganichalides, phosphates, sulfates, organic halogens or organic phosphates.

The fire barrier layer may be directly or indirectly coated onto a film,for example, without limitation, by roll or reverse roll coating,gravure or reverse gravure coating, transfer coating, spray coating,brush coating, dip coating, tape casting, doctor blading, slot-diecoating, or deposition coating. In certain embodiments, the fire barrierlayer is coated onto the film as a slurry of the ingredients in asolvent, such as water, and is allowed to dry prior to incorporationinto the fire barrier laminate. The fire barrier layer may be created asa single layer or coating, thus utilizing a single pass, or may becreated by utilizing multiple passes, layers or coatings. By utilizingmultiple passes, the potential for formation of defects in the firebarrier layer is reduced. If multiple passes are desired, the second andpossible subsequent passes may be formed onto the first pass while thefirst pass is still substantially wet, i.e. prior to drying, such thatthe first and subsequent passes are able to form a single unitary firebarrier layer upon drying.

When multiple passes, layers or coating of the fire barrier layer areutilized, it is possible to vary the amounts of the ingredients in eachpass, layer or coating, such that the passes, layers or coatings mayhave different amounts of, for example, inorganic platelet material. Incertain embodiments, at least one pass, layer or coating having agreater amount of inorganic platelet material may be present on the “hotface” of the fire barrier layer. Further, in certain embodiments anotherpass, layer or coating may have a greater amount of functional filler inorder to reduce the amount of defects present in the pass, layer orcoating, and may have a greater ability to correct defects present in aprevious pass, layer or coating.

In certain embodiments, the fire barrier layer may be directly orindirectly coated onto a first polymeric flame propagation resistantfilm, such as but not limited to polyesters, polyimides,polyetherketones, polyetheretherketones, polyvinylfluorides, polyamides,polytetrafluoroethylenes, polyaryl sulfones, polyester amides, polyesterimides, polyethersulfones, polyphenylene sulfides, ethylenechlorotrifluoroethylene, combinations thereof, and the like.Commercially available examples of these films are films sold by E.I.DuPont de Nemours & Co. of Wilmington, Del., such as a polyester filmsold under the trade designation MYLAR®, a polyvinylfluoride film soldunder the trade designation TEDLAR®, and a polyimide film sold under thetrade designation KAPTON®, a polyetheretherketone film sold under thetrade designation APTIV® by Victrex, plc. of Lancashire, UK, apolyetheretherketone film sold under the trade designation KFTASPIRE®and an ethylene chlorotrifluoroethylene film sold under the tradedesignation HALAR® by Solvay SA of Brussels, Belgium, and the like. Thefirst polymeric flame propagation resistant film may be metalized tominimize moisture absorption, particularly on the outboard side, butoptionally on the inboard side also.

In certain embodiments, the first polymeric flame propagation resistantfilm and/or the metalized first polymeric flame propagation resistantfilm may have an opaque, low-gloss polymer coating, optionallycontaining a fire retardant additive. The fire retardant additives maycomprise at least one of antimony compounds, hydrated alumina compounds,borates, carbonates, bicarbonates, inorganic halides, phosphates,sulfates, organic halogens or organic phosphates.

The fire barrier laminate may additionally include an adhesive on one ofthe outer surfaces to facilitate thermal or other energetic bonding ofthe laminate to companion backside films as currently practiced in thefabrication of thermal acoustic insulation blankets to form a covering,bag, or envelope for the insulation layers. In some embodiments, apartially or substantially totally encapsulated insulation system isformed. (Air holes may be employed to accommodate pressure variationduring flight.) In certain embodiments, the adhesive comprises anadhesive which is activated by the application of ultrasonic or radiofrequency energy, or the like.

Optionally, at least one scrim layer may be disposed within the adhesiveor a surface adjacent to an adhesive on at least one side of, or within,the fire barrier laminate, in order to, for example, add strength to thelaminate, including puncture or tear resistance. In certain embodiments,a scrim may be disposed between the at least one non-fibrous firebarrier layer and the first polymeric flame propagation resistant filmlayer, such that the non-fibrous fire barrier layer may be coatedindirectly onto the flame propagation resistant film layer by coatingthe non-fibrous fire barrier layer onto the scrim. The scrim may be inthe form of a mesh, and may comprise fiberglass, nylon, polyester (suchas aromatic polyester), aramid (such as para-aramid), or high orultra-high molecular weight polyethylene in various embodiments, or maybe absent.

The fire barrier laminate may additionally include adhesives, internalto the fire barrier laminate, which are utilized to laminate orotherwise adhere the layers of the fire barrier laminate to one another.These adhesives may include thermally activated or pressure-basedadhesives. The adhesives may comprise at least one of polyester basedadhesives or polyvinyl fluoride based adhesives, and/or siliconeadhesives. In certain embodiments, the adhesives may contain fireretardant additives. The fire retardant additives may comprise at leastone of antimony compounds, hydrated alumina compounds, borates,carbonates, bicarbonates, inorganic halides, phosphates, sulfates,organic halogens or organic phosphates.

As shown in FIG. 1A, an embodiment of a thermal acoustic insulationsystem 10, or “blanket”, is depicted in cross-section, in which twoinsulating layers 14, such as one inch thick MICROLITE AA® Premium NRfiberglass insulation (0.42 pcf) (available from Johns ManvilleInternational, Inc.), are disposed within a covering of an exteriorlyfacing fire barrier laminate 16, and an interiorly facing inboard coverfilm 18 (optionally, a second fire barrier laminate). The insulatinglayers 14 may also or alternatively comprise polyimide foam insulation.The exteriorly facing laminate 16 and the inboard film 18 may be heatsealed with an adhesive 12 to partially or substantially totally envelopor encapsulate the fiberglass insulation layers. Flames 20, depictingthe FAA test procedures, are shown proximate to the exteriorly facingfire barrier laminate 16.

A detailed section of an embodiment of the fire barrier laminate 16,encircled as B′ in FIG. 1A is shown in an exploded cross-sectional viewin FIG. 1B. The fire barrier laminate 16 is constructed by firstapplying an adhesive 104 to a first polymeric flame propagationresistant film 106, such as a polyetheretherketone film. The firebarrier layer 102 is then coated onto the adhesive 104-coated firstpolymeric film 106. Alternatively, the adhesive 104 may be omitted,resulting in the fire barrier layer 102 being coated directly onto thefirst polymeric film 106. The fire barrier layer 102 may comprise apaste or slurry type material with an amount of water or other solventbeing present in the fire barrier layer 102 as it is being coated ontothe first polymeric film 106. In this instance, the fire barrier layer102 is allowed to dry before continued processing. Optionally, awater-repellant material may be incorporated in, coated onto orsaturated/impregnated into the fire barrier layer 102.

Separately, a scrim layer 108, such as a fiberglass or nylon scrim, islaminated to a second film 110, such as a polyetheretherketone film,using an adhesive 114. An adhesive 112 is also used to laminate the firebarrier layer 102-coated first polymeric film 106 to the scrim layer108. Alternatively, the scrim layer 108 may be adhered to the firebarrier layer 102 prior to laminating the scrim layer 108 to the secondfilm 110.

Optionally, the assembled fire barrier laminate 16 includes anencapsulating adhesive layer 116 adjacent to the first polymeric film106 in order to encapsulate the insulation layers 14 between the firebarrier laminate 16 and the inboard film 18. Additionally oralternatively, the fire barrier laminate 16 may utilize mechanicalfasteners or tapes for encapsulating the insulating layers 14 betweenthe fire barrier laminate 16 and the inboard film 18.

A detailed section of another embodiment of the fire barrier laminate16, encircled as B′ in FIG. 1A is shown in an exploded cross-sectionalview in FIG. 1C. The fire barrier laminate 16 is constructed by firstapplying an adhesive 204 to a first polymeric flame propagationresistant film 206, such as an ethylene chlorotrifluoroethylene film.The fire barrier layer 202 is then coated onto the adhesive 204-coatedfirst polymeric film 206. Alternatively, the adhesive 204 may beomitted, resulting in the fire barrier layer 202 being coated directlyonto the first polymeric film 206. The fire barrier layer 202 maycomprise a paste or slurry type material with an amount of water orother solvent being present in the fire barrier layer 202 as it is beingcoated onto the first polymeric film 206. In this instance, the firebarrier layer 202 is allowed to dry before continued processing.Optionally, a water-repellant material may be incorporated in, coatedonto or saturated/impregnated into the fire barrier layer 202.

A second film 210, such as a metalized polyetheretherketone film, islaminated to the fire barrier layer 202-coated first polymeric film 206using an adhesive 212. The fire barrier laminate 16 includes a scrimlayer 208 laminated to the first polymeric film 206 opposite the firebarrier layer 202 via an adhesive layer 216.

A detailed section of a further embodiment of the fire barrier laminate16, encircled as B′ in FIG. 1A is shown in an exploded cross-sectionalview in FIG. 1D. The fire barrier laminate 16 is constructed by firstapplying an adhesive 304 to a first polymeric flame propagationresistant film 306, such as a metalized polyetheretherketone film. Thefire barrier layer 302 is then coated onto the adhesive 304-coated firstpolymeric film 306. Alternatively, the adhesive 304 may be omitted,resulting in the fire barrier layer 302 being coated directly onto thefirst polymeric film 306. The fire barrier layer 302 may comprise apaste or slurry type material with an amount of water or other solventbeing present in the fire barrier layer 302 as it is being coated ontothe first polymeric film 306. In this instance, the fire barrier layer302 is allowed to dry before continued processing. Optionally, a waterrepellant material may be incorporated in, coated onto orsaturated/impregnated into the fire barrier layer 302.

Separately, a scrim layer 308, such as a fiberglass or nylon scrim, islaminated to a second film 310, such as a polyetheretherketone film. Anadhesive 312 is also used to laminate the fire barrier layer 302-coatedfirst polymeric film 306 to the scrim layer 308. Alternatively, thescrim layer 308 may be adhered to the fire barrier layer 302 prior tolaminating the scrim layer 308 to the second film 310.

The assembled fire barrier laminate 16 may include an encapsulatingadhesive layer 316 adjacent to the first polymeric film 306 in order toencapsulate the insulation layers 14 between the fire barrier laminate16 and the inboard film 18. A second scrim layer 308 a is optionallyembedded in the adhesive layer 316.

A detailed section of a further embodiment of the fire barrier laminate16, encircled as B′ in FIG. 1A is shown in an exploded cross-sectionalview in FIG. 1E. The fire barrier laminate 16 is constructed by firstapplying an adhesive 404 to a first polymeric flame propagationresistant film 406, such as a polyetheretherketone film. A second scrimlayer 408 a is optionally laminated between the adhesive 404 and thefirst polymeric film 406. The fire barrier layer 402 is then coated ontothe adhesive 404-coated first polymeric film 406. Alternatively, theadhesive 404 may be omitted, resulting in the fire barrier layer 402being coated directly onto the first polymeric film 406. The firebarrier layer 402 may comprise a paste or slurry type material with anamount of water or other solvent being present in the fire barrier layer402 as it is being coated onto the first polymeric film 406. In thisinstance, the fire barrier layer 402 is allowed to dry before continuedprocessing. Optionally, a water repellant material may be incorporatedin, coated onto or saturated/impregnated into the fire barrier layer402.

A second film 410, such as a metalized polyetheretherketone film, islaminated to the fire barrier layer 402-coated first polymeric film 406using an adhesive 412. The fire barrier laminate 16 includes a scrimlayer 408 laminated to the first polymeric film 406 opposite the firebarrier layer 402 via an adhesive layer 416.

In a first embodiment, a subject fire barrier laminate may comprise: atleast one non-fibrous fire barrier layer directly or indirectly coatedonto at least one first polymeric flame propagation resistant filmlayer; at least one second film layer proximate to the non-fibrous firebarrier layer opposite the first polymeric flame propagation resistantfilm layer; at least one scrim layer disposed: (i) between thenon-fibrous fire barrier layer and the first polymeric flame propagationresistant film layer; and/or (ii) between the non-fibrous fire barrierlayer and the second film layer; and/or (iii) proximate to the firstpolymeric flame propagation resistant film layer opposite thenon-fibrous fire barrier layer; and/or (iv) proximate to the second filmlayer opposite the non-fibrous fire barrier layer; optionally, awater-repellant material incorporated into and/or applied to thenon-fibrous fire barrier layer; optionally at least one adhesive layeradhering the non-fibrous fire barrier layer to the first polymeric flamepropagation resistant film layer; and optionally at least one adhesivelayer adhering the scrim layer to at least one of the non-fibrous firebarrier layer, the first polymeric flame propagation resistant filmlayer, or the second film layer; wherein the non-fibrous fire barrierlayer comprises at least one inorganic platelet material, optionally atleast one organic binder and/or inorganic binder, and optionally atleast one functional filler.

The fire barrier laminate of the first embodiment may further includethat the inorganic platelet material comprises at least one ofvermiculite, mica, clay or talc. The vermiculite may be exfoliated andoptionally defoliated. The clay may comprise at least one of ball clay,bentonite, smectite, hectorite, kaolinite, montmorillonite, saponite,sepiolite or sauconite.

The fire barrier laminate of either or both of the first or subsequentembodiments may further include that the organic binder comprises atleast one of acrylic latex, (meth)acrylic latex, phenolic resins,copolymers of styrene and butadiene, vinylpyridine, acrylonitrile,copolymers of acrylonitrile and styrene, vinyl chloride, polyurethane,copolymers of vinyl acetate and ethylene, polyamides, silicones,unsaturated polyesters, epoxy resins or polyvinyl esters.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that the inorganic binder comprises at least one ofcolloidal alumina, colloidal silica or colloidal zirconia.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that the non-fibrous fire barrier layer comprisesfrom about 20% to about 100% by weight of the inorganic plateletmaterial, from 0% to about 40% by weight of the organic binder and/orinorganic binder, and from 0% to about 50% of the functional filler.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that the non-fibrous fire barrier layer comprisesfrom about 60% to about 100% by weight of the inorganic plateletmaterial, from 0% to about 20% by weight of the organic binder and/orinorganic binder, and from 0% to about 20% of the functional filler.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that either or both of the first polymeric flamepropagation resistant film layer or the second film layer comprises atleast one of polyesters, polyimides, polyetherketones,polyetheretherketones, polyvinylfluorides, polyamides,polytetrafluoroethylenes, polyaryl sulfones, polyester amides, polyesterimides, polyethersulfones, polyphenylene sulfides, ethylenechlorotrifluoroethylene, or combinations thereof.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that the at least one scrim layer comprises at leastone of fiberglass, nylon, polyester, aramid, or high or ultra-highmolecular weight polyethylene.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that either or both of the first polymeric flamepropagation resistant film layer and the second film layer aremetalized. Either or both of the first polymeric flame propagationresistant film layer or the second film layer have an opaque, low-glosspolymer coating, optionally including a fire retardant additive.

The fire barrier laminate of any of the first or subsequent embodimentsmay have a basis weight of less than about 120 gsm.

In a second embodiment, a subject thermal acoustic insulation system maycomprise a plurality of insulating layers disposed within a covering ofan exteriorly facing fire barrier laminate as in any of the first orsubsequent embodiments, and an interiorly facing inboard cover film.

The thermal acoustic insulation system of the second embodiment mayfurther include that the interiorly facing cover film also comprises thefire barrier laminate.

The thermal acoustic insulation system of either or both of the secondor subsequent embodiments may further include that the exteriorly facingfire barrier laminate and the interiorly facing inboard cover film aresealed with an adhesive to partially or substantially totally envelop orencapsulate the plurality of insulating layers.

The thermal acoustic insulation system of any of the second orsubsequent embodiments may further include that the insulating layerscomprise fiberglass insulation and/or polyimide foam insulation.

The thermal acoustic insulation system of any of the second orsubsequent embodiments may be capable of passing the flame propagationand burn-through resistance test protocols of 14 C.F.R. §§ 25.856(a) and(b), Appendix F, Parts VI and VII.

In a third embodiment, a subject method of making a fire barrierlaminate may comprise: directly or indirectly coating at least onenon-fibrous fire barrier layer onto a first polymeric flame propagationresistant film layer; laminating the non-fibrous fire barrier layer withat least one second film layer, wherein the second film layer isproximate to the non-fibrous fire barrier layer; and laminating at leastone scrim layer within the fire barrier laminate, wherein the at leastone scrim layer is disposed: (i) between the non-fibrous fire barrierlayer and the first polymeric flame propagation resistant film layer;and/or (ii) between the non-fibrous fire barrier layer and the secondfilm layer; and/or (iii) proximate to the first polymeric flamepropagation resistant film layer opposite the non-fibrous fire barrierlayer; and/or (iv) proximate to the second film layer opposite thenon-fibrous fire barrier layer; wherein the non-fibrous fire barrierlayer comprises at least one inorganic platelet material, optionally atleast one organic binder and/or inorganic binder, and optionally atleast one functional filler; and wherein the non-fibrous fire barrierlayer optionally contains a water repellant material, and/or the methodfurther comprises optionally coating and/or saturating the non-fibrousfire barrier layer with a water repellant material.

The method of the third embodiment may further include that theinorganic platelet material comprises at least one of vermiculite, mica,clay or talc. The vermiculite may be exfoliated and optionallydefoliated.

The method of either or both of the third or subsequent embodiments mayfurther include that the organic binder comprises at least one ofacrylic latex, (meth)acrylic latex, phenolic resins, copolymers ofstyrene and butadiene, vinylpyridine, acrylonitrile, copolymers ofacrylonitrile and styrene, vinyl chloride, polyurethane, copolymers ofvinyl acetate and ethylene, polyamides, silicones, unsaturatedpolyesters, epoxy resins or polyvinyl esters.

The method of any of the third or subsequent embodiments may furtherinclude that the inorganic binder comprises at least one of colloidalalumina, colloidal silica or colloidal zirconia.

The method of any of the third or subsequent embodiments may furtherinclude that the non-fibrous fire barrier layer comprises from about 20%to about 100% by weight of the inorganic platelet material, from 0% toabout 40% by weight of the organic binder and/or inorganic binder, andfrom 0% to about 50% of the functional filler.

The method of any of the third or subsequent embodiments may furtherinclude that either or both of the first polymeric flame propagationresistant film layer or the second film layer comprises at least one ofpolyesters, polyimides, polyetherketones, polyetheretherketones,polyvinylfluorides, polyamides, polytetrafluoroethylenes, polyarylsulfones, polyester amides, polyester imides, polyethersulfones,polyphenylene sulfides, ethylene chlorotrifluoroethylene, orcombinations thereof.

The method of any of the third or subsequent embodiments may furtherinclude that the at least one scrim layer comprises at least one offiberglass, nylon, polyester, aramid, or high or ultra-high molecularweight polyethylene.

The method of any of the third or subsequent embodiments may furtherinclude that either or both of the first polymeric flame propagationresistant film layer or the second film layer are metalized. Either orboth of the first polymeric flame propagation resistant film layer orthe second film layer may be coated with an opaque, low-gloss polymer,optionally including a fire retardant additive.

Non-Fibrous Fire Barrier Layer Comprising Inorganic Pigment Material

In one embodiment, the present fire barrier layer provided is anon-fibrous fire-barrier layer that is incorporated into a fire barrierlaminate, wherein the fire barrier layer comprises a film of at leastone inorganic pigment material. The at least one inorganic pigmentmaterial may provide superior thermal conductivity and/or heatreflective properties, thus spreading the incident thermal energy alongthe entire surface of the fire-barrier, the preventing the formation ofhot spots.

In one embodiment, the subject fire barrier laminate comprises:

-   -   a. a first film layer;    -   b. a support layer;    -   c. at least one non-fibrous fire barrier layer; and    -   d. optionally, a second film layer.

In one embodiment, the second film layer is applied to the non-fibrousfire barrier layer using an adhesive.

In one embodiment, the non-fibrous fire barrier layer comprises at leastone inorganic pigment material. In one embodiment, the at least oneinorganic pigment material is a metal oxide-coated inorganic plateletmaterial. In one embodiment, the metal oxide-coated inorganic plateletmaterial is metal oxide-coated mica platelets.

In an alternate embodiment, the subject fire barrier film laminate lacksthe second film layer.

In one embodiment, the support layer comprises a fibrous layer and anadhesive.

In one embodiment, the support layer is a fibrous layer.

In one embodiment, a scrim layer is laminated to the first film layer onthe opposite surface to the support layer using an adhesive. In analternate embodiment, the scrim layer is laminated to the first filmlayer on the same side as the support layer.

Construction of the Fire-Barrier Laminate

Referring to FIG. 2, in one embodiment, the present fire barrierlaminate may comprise a first film layer (500), with a support layer(501) coated onto the top surface of the first film layer (500). Thesupport layer (501) comprises a fibrous layer (502) in a first adhesivelayer (503). A non-fibrous fire barrier layer (504) is coated onto thesupport layer (501). A second adhesive layer (505) is coated onto thenon-fibrous fire barrier layer (504), onto which a second film layer(506) is overlaid. In one embodiment, the second adhesive layer (505)and the second film layer (506) are absent.

Referring to FIG. 2, in an alternate embodiment, the present firebarrier laminate may comprise a scrim (507) that is laminated to thebottom surface of the first film layer (500) using an adhesive (508).The first film layer (500) has a support layer (501) coated onto the topsurface of the first film layer (500). The support layer (501) comprisesa fibrous layer (502) in a first adhesive layer (503). A non-fibrousfire barrier layer (504) is coated onto the support layer (501). Asecond adhesive layer (505) is coated onto the non-fibrous fire barrierlayer (504), onto which a second film layer (506) is overlaid. In oneembodiment, the second adhesive layer (505) and the second film layer(506) are absent.

In one embodiment, non-fibrous fire barrier layer (504) comprises atleast one inorganic pigment material. In one embodiment, the at leastone inorganic pigment material is a metal oxide-coated inorganicplatelet material. In one embodiment, the metal oxide-coated inorganicplatelet material is metal oxide-coated mica platelets.

In one embodiment, the adhesive (508) is an adhesive that requires theapplication of ultrasonic or radio frequency energy, or heat, or thelike to activate it.

In one embodiment, the adhesive (508) is a heat seal adhesive.

In one embodiment, the scrim (507) that is laminated to the bottomsurface of the first film layer (500) using an adhesive (508) is aprefabricated component, onto which the support layer (501), thenon-fibrous fire barrier layer (504), second adhesive (505) and secondfilm layer (506) is added. In one embodiment, the prefabricatedcomponent comprises a scrim and a high temperature thermoplastic filmwith a high strength:weight ratio. One of ordinary skill in the art canreadily appreciate that any a high temperature thermoplastic film with ahigh strength:weight ratio is suitable for use in the present invention.

In one embodiment, the high temperature thermoplastic film is comprisedof a material selected from the group consisting of: polyesters,polyimides, polyetherketones, polyetheretherketones, polyvinylfluorides,polyamides, polytetrafluoroethylenes, polyaryl sulfones, polyesteramides, polyester imides, polyethersulfones, polyphenylene sulfides,ethylene chlorotrifluoroethylene, and combinations thereof.

In one embodiment, the high temperature thermoplastic film ismetallized.

In one embodiment, the scrim (507) that is laminated to the bottomsurface of the first film layer (500) using an adhesive (508) isprovided prefabricated as a commercially available product, onto whichthe support layer (501), the non-fibrous fire barrier layer (504),second adhesive (505) and second film layer (506) is added. In oneembodiment, the commercially available product is a laminate containinga scrim and a polyetheretherketone film, such as the laminate sold underthe trade designation LAMAGUARD 131MD. In an alternate embodiment, thecommercially available product is a laminate containing a scrim, and apolyetheretherketone film, such as the laminate sold under the tradedesignation LAMAGUARD 110.

This composition provides a light basis weight article with surprisingresistance to damage associated with handling and use along with theability to resist flame propagation and flame penetration as defined in14 C.F.R. §§ 25.856(a) and (b). The term “basis weight” is defined asthe weight per unit area, typically defined in grams per square meter(gsm). The subject fire barrier layer, and the laminate incorporatingit, are therefore useful in providing fire burn-through protection forthermal and acoustical insulation structures, referred to in theindustry as “blankets”, for commercial aircraft fuselages, as thesubject fire barrier laminate may have a basis weight less than about110 gsm, in certain embodiments between about 50 gsm to about 110 gsm,and in certain embodiments between about 90 gsm to about 105 gsm.

Referring to FIG. 3, in one embodiment, the present fire barrierlaminate may comprise a first film layer (500), with a support layer(501) coated onto the top surface of the first film layer (500). Thesupport layer (501) comprises a fibrous layer (502) in a first adhesive(503). A non-fibrous fire barrier layer (504) is coated onto the supportlayer (501). A second support layer (509) is coated on to thenon-fibrous fire barrier layer (504). The second support layer (509)comprises a fibrous layer (502) and a first adhesive layer (503). Asecond adhesive layer (505) is coated onto the second support layer(509), onto which a second film layer (506) is overlaid. In oneembodiment, the second adhesive layer (505) and the second film layer(506) are absent.

Referring to FIG. 3, in an alternate embodiment, the present firebarrier laminate may comprise a scrim (507) that is laminated to thebottom surface of the first film layer (500) using an adhesive (508).The first film layer (500) has a support layer (501) coated onto the topsurface of the first film layer (500). The support layer (501) comprisesa fibrous layer (502) in a first adhesive layer (503). A non-fibrousfire barrier layer (504) is coated onto the support layer (501). Asecond support layer (509) is coated on to the non-fibrous fire barrierlayer (504). The second support layer (509) comprises a fibrous layer(502) and a first adhesive (503). A second adhesive layer (505) iscoated onto the second support layer (509), onto which a second filmlayer (506) is overlaid. In one embodiment, the second adhesive layer(505) and the second film layer (506) are absent.

Referring to FIG. 4, in one embodiment, the present fire barrierlaminate may comprise a first film layer (500) onto which a fibrouslayer (502) is overlaid. A non-fibrous fire barrier layer (504) iscoated onto the fibrous layer (502). A third adhesive layer (510) iscoated onto the non-fibrous fire barrier layer (504), onto which asecond film layer (506) is overlaid. In one embodiment, the thirdadhesive layer (510) and the second film layer (506) are absent.

Referring to FIG. 4, in an alternate embodiment, the present firebarrier laminate may comprise a scrim (507) that is laminated to thebottom surface of the first film layer (500) using a heat seal adhesive(508). A fibrous layer (502) is overlaid on to the top surface of thefirst film layer (500). A non-fibrous fire barrier layer (504) is coatedonto the fibrous layer (502). A third adhesive layer (510) is coatedonto the non-fibrous fire barrier layer (504), onto which a second filmlayer (506) is overlaid. In one embodiment, the third adhesive layer(510) and the second film layer (506) are absent.

Referring to FIG. 5, in one embodiment, the present fire barrierlaminate may comprise a first film layer (500) onto which a fibrouslayer (502) is overlaid. A non-fibrous fire barrier layer (504) iscoated onto the fibrous layer (502). A second film layer (506) isoverlaid on to the non-fibrous fire barrier layer (504). In oneembodiment, the second film layer (506) is absent.

Referring to FIG. 5, in an alternate embodiment, the present firebarrier laminate may comprise a scrim (507) that is laminated to thebottom surface of the first film layer (500) using a heat seal adhesive(508). A fibrous layer (502) is overlaid on to the top surface of thefirst film layer (500). A non-fibrous fire barrier layer (504) is coatedonto the fibrous layer (502). A second film layer (506) is overlaid onto the non-fibrous fire barrier layer (504). In one embodiment, thesecond film layer (506) is absent.

Referring to FIG. 6, in one embodiment, the present fire barrierlaminate may comprise a first film layer (500) coated with a firstadhesive (503), onto which a fibrous layer (502) is overlaid. Anon-fibrous fire barrier layer (504) is coated onto the fibrous layer(502). A second adhesive layer (505) is coated onto the non-fibrous firebarrier layer (504), onto which a second film layer (506) is overlaid.In one embodiment, the second adhesive layer (505) and the second filmlayer (506) are absent.

Referring to FIG. 6, in an alternate embodiment, the present firebarrier laminate may comprise a scrim (507) that is laminated to thebottom surface of the first film layer (500) using a heat seal adhesive(508). The top surface of the first film layer is coated with a firstadhesive (503), onto which a fibrous layer (502) is overlaid. Anon-fibrous fire barrier layer (504) is coated onto the fibrous layer(502). A second adhesive layer (505) is coated onto the non-fibrous firebarrier layer (504), onto which a second film layer (506) is overlaid.In one embodiment, the second adhesive layer (505) and the second filmlayer (506) are absent.

Referring to FIG. 7, in one embodiment, the present fire barrierlaminate may comprise a first film layer (500) coated with a firstadhesive layer (503), onto which a fibrous layer (502) is overlaid. Anon-fibrous fire barrier layer (504) is coated onto the fibrous layer(502), onto which a second film layer (506) is overlaid. In oneembodiment, the second film layer (506) is absent.

Referring to FIG. 7, in an alternate embodiment, the present firebarrier laminate may comprise a scrim (507) that is laminated to thebottom surface of the first film layer (500) using a heat seal adhesive(508). The top surface of the first film layer is coated with a firstadhesive (503), onto which a fibrous layer (502) is overlaid. Anon-fibrous fire barrier layer (504) is coated onto the fibrous layer(502), onto which a second film layer (506) is overlaid. In oneembodiment, the second film layer (506) is absent.

In one embodiment, the first adhesive (503) is a first pressuresensitive adhesive. In one embodiment, the first pressure sensitiveadhesive is a silicone pressure sensitive adhesive.

In one embodiment, the second adhesive (505) is a second pressuresensitive adhesive. In one embodiment, the second pressure sensitiveadhesive is a silicone pressure sensitive adhesive.

In one embodiment, the third adhesive (510) is a third pressuresensitive adhesive. In one embodiment, the second pressure sensitiveadhesive is a silicone pressure sensitive adhesive.

The pressure sensitive adhesive may be utilized at any concentration. Inone embodiment, the pressure sensitive adhesive is dissolved in asolvent. In one embodiment, the solvent has a dielectric constant lessthan 30. In one embodiment, the solvent is selected from the groupconsisting of xylene, IPA, acetone, ethyl acetate, toluene andcombinations thereof.

In one embodiment, a scrim (507) is laminated to the bottom surface ofthe first film layer (500) using an adhesive (508). The scrim (507) maybe in the form of a mesh, and may comprise fiberglass, nylon, polyester(such as aromatic polyester), aramid (such as para-aramid), or high orultra-high molecular weight polyethylene, or combinations thereof.

In one embodiment, the adhesive (508) is an adhesive that requires theapplication of ultrasonic or radio frequency energy, or heat, or thelike to activate it.

In one embodiment, the adhesive (508) is a heat seal adhesive.

In one embodiment, the scrim (507) that is laminated to the bottomsurface of the first film layer (500) using an adhesive (508) is aprefabricated component, onto which the support layer (501), thenon-fibrous fire barrier layer (504), second adhesive (505) and secondfilm layer (506) is added. In one embodiment, the prefabricatedcomponent comprises a scrim and a high temperature thermoplastic filmwith a high strength:weight ratio. One of ordinary skill in the art canreadily appreciate that any a high temperature thermoplastic film with ahigh strength:weight ratio is suitable for use in the present invention.

In one embodiment, the high temperature thermoplastic film is comprisedof a material selected from the group consisting of: polyesters,polyimides, polyetherketones, polyetheretherketones, polyvinylfluorides,polyamides, polytetrafluoroethylenes, polyaryl sulfones, polyesteramides, polyester imides, polyethersulfones, polyphenylene sulfides,ethylene chlorotrifluoroethylene, and combinations thereof.

In one embodiment, the scrim (507) that is laminated to the bottomsurface of the first film layer (500) using an adhesive (508) isprovided prefabricated as a commercially available product, onto whichthe support layer (501), the non-fibrous fire barrier layer (504),second adhesive (505) and second film layer (506) is added. In oneembodiment, the commercially available product is a laminate containinga polyetheretherketone film, such as the laminate sold under the tradedesignation LAMAGUARD 131MD. In an alternate embodiment, thecommercially available product is a laminate containing apolyetheretherketone film, such as the laminate sold under the tradedesignation LAMAGUARD 110.

It can be readily appreciated that the present fire barrier laminatesmay be fabricated in any manner: i.e. the fire barrier laminate may befabricated using the first film layer as the foundation on which allsubsequent layers are added. Alternatively, the barrier laminate may befabricated using the second film layer as the foundation on which allsubsequent layers are added. Alternatively, the fire barrier laminatemay be fabricated using a method where certain layers are added to thefirst film layer, and certain layers are added to the second film layer,forming two halves of the final laminate, and the two halves may becombined.

The non-fibrous fire-barrier layer (504) may be directly coated onto thesupport layer (501), for example, without limitation, by roll or reverseroll coating, gravure or reverse gravure coating, transfer coating,spray coating, brush coating, dip coating, tape casting, doctor blading,slot-die coating, or deposition coating. In certain embodiments, thenon-fibrous fire-barrier layer (504) is coated onto the support layer(501) as a slurry of the ingredients in a solvent, and is allowed to dryprior to incorporation into the fire-barrier laminate. The non-fibrousfire-barrier layer (504) may be created as a single layer or coating,thus utilizing a single pass, or may be created by utilizing multiplepasses, layers or coatings. If multiple passes are desired, the secondand possible subsequent passes may be formed onto the first pass whilethe first pass is still substantially wet, i.e. prior to drying, suchthat the first and subsequent passes are able to form a single unitaryfire barrier layer upon drying. Alternatively, if multiple passes aredesired, the second and possible subsequent passes may be formed ontothe first pass or each subsequent pass has dried.

When multiple passes, layers or coatings of the non-fibrous fire-barrierlayer (504) are utilized, it is possible to vary the amounts of theingredients in each pass, layer or coating, such that the passes, layersor coatings may have different amounts of, for example, the at least oneinorganic pigment material. In certain embodiments, at least one pass,layer or coating having a greater amount of the at least one inorganicpigment material may be present on the “hot face” of the fire barrierlayer. Further, in certain embodiments another pass, layer or coatingmay be formulated so as to reduce the amount of defects present in thepass, layer or coating, and may have a greater ability to correctdefects present in a previous pass, layer or coating.

The fire barrier laminate may additionally include an adhesive on one ofthe outer surfaces to facilitate thermal or other energetic bonding ofthe laminate to companion backside films as currently practiced in thefabrication of thermal acoustic insulation blankets to form a covering,bag, or envelope for the insulation layers. In some embodiments, apartially or substantially totally encapsulated insulation system isformed. (Air holes may be employed to accommodate pressure variationduring flight.) In certain embodiments, the adhesive comprises anadhesive which is activated by the application of ultrasonic or radiofrequency energy, or the like.

In certain embodiments that may be utilized in aviation applications,the amount of materials comprising the other elements of the presentfire barrier laminate are reduced, to maximize the amount of materialthat comprises the non-fibrous fire barrier layer (504) comprising atleast one inorganic pigment material. In certain embodiments, thenon-fibrous fire barrier layer (504) comprising at least one inorganicpigment material is present in a range from about 10 gsm to about 100gsm. In certain embodiments, the non-fibrous fire barrier layer (504)comprising at least one inorganic pigment material is about 25 gsm.

In one embodiment, the fibrous layer (502) is present in the laminate ina range from about 16 gsm to about 33 gsm.

The at Least One Inorganic Pigment Material

Any inorganic pigment material that is capable of forming a non-fibrousfire-barrier layer with a resistance to heat of at least 16.0±0.8Btu/ft² sec (18.2±0.9 W/cm²) and resistance to a temperature of about1900 degrees Fahrenheit may be utilized in the present fire barrierlaminate. The at least one inorganic pigment material may be any size.

While any size inorganic pigment material may be used, inorganic pigmentmaterials with larger relative diameters and high diameter to thicknessaspect ratios may be desirable due to their increased flame propagationand/or burnthrough resistance performance, as well as other propertiessuch as flexibility and processibility.

In certain embodiments, the at least one inorganic pigment material mayhave a diameter of from about 1 μm to about 300 μm. In furtherembodiments, the at least one inorganic pigment material may have adiameter of from about 1 μm to about 150 μm. In certain embodiments, thenon-fibrous fire barrier layer may be formed using a preparation ofinorganic pigment material of uniform particle size. In alternateembodiments, the non-fibrous fire barrier layer may be formed using apreparation of inorganic pigment material of non-uniform particle sizes.

In certain embodiments, the at least one inorganic pigment material mayhave an aspect ratio of from about 50:1 to about 2000:1. In certainembodiments, the at least one inorganic pigment material may have anaspect ratio of from about 50:1 to about 1000:1. In further embodiments,the at least one inorganic pigment material may have an aspect ratio offrom about 200:1 to about 800:1.

In one embodiment, the at least one inorganic pigment material is ametal oxide-coated inorganic platelet material. In one embodiment, themetal oxide-coated inorganic platelet material is metal oxide-coatedmica platelets. The mica can be natural or synthetic, and any plateletis suitable for use in the present fire barrier laminate. Suitable micasmay include, without limitation, muscovite, phlogopite, vermiculite,suzorite, biotite, and may include synthetic micas such asfluorophlogopite.

In one embodiment the metal oxide layer coating is selected from thegroup consisting of titanium oxide, iron oxide, chromium oxide, tinoxide, silicon oxide, cobalt oxide, antimony oxide, and any combinationthereof.

The thickness of the metal oxide coating, and/or the choice of metaloxide can be varied to alter the properties of the at least oneinorganic pigment material and/or the fire barrier layer that may beformed from the at least one inorganic pigment material. The propertiesthat may be altered include, for example, the refractive index, the heatconductivity, the heat-reflective properties of the at least oneinorganic pigment material, or the wavelength(s) of electromagneticradiation that are reflected by the at least one inorganic pigmentmaterial.

One, or more than one inorganic pigment material can be used to form thenon-fibrous fire barrier layer of the present fire barrier laminate. Forexample, in one embodiment, the non-fibrous fire barrier layer is madeusing a mixture of inorganic pigment materials, wherein the mixturecomprises pigments of different colors, the choice of which offers awider spectrum of wavelengths that can be reflected than a singlepigment alone. In another embodiment, the mixture comprises pigments ofdifferent sizes. In another embodiment, the mixture comprises pigmentsof different aspect ratios. In an alternate embodiment, the mixturecomprises pigments of different sizes, colors, aspect ratio, or anycombination thereof.

The at least one inorganic pigment material may be coated with anadditional coating. In one embodiment, the additional coating isselected from the group consisting of silane, calcium borate, carbonblack, and any combination thereof.

In one embodiment, the at least one inorganic pigment material comprisesspecial effects pigments (also referred to as nacreous pigments).Special effects pigments comprise a metal oxide coating on a substrateplatelet. In one embodiment, the substrate platelet is selected from thegroup consisting of silica, alumina, borosilicate and mica. The mica canbe natural or synthetic, and any platelet is suitable for use in thepresent fire barrier laminate. Suitable micas may include, withoutlimitation, muscovite, phlogopite, vermiculite, suzorite, biotite, andmay include synthetic micas such as fluorophlogopite.

In one embodiment the metal oxide layer coating is selected from thegroup consisting of titanium oxide, iron oxide, chromium oxide, tinoxide, silicon oxide, cobalt oxide, antimony oxide, and any combinationthereof.

The at least one inorganic pigment material may also be combined withfurther platelet materials, such as, for example, mica or talc. Ifpresent, further platelet may be included in the fire barrier layer inan amount from about 1 to about 50 weight percent, in certainembodiments, from about 10 to about 30 weight percent, based on thetotal weight of the fire-barrier layer. However, the incorporation offurther platelet materials should not be detrimental to the performanceof the fire-barrier layer.

In one embodiment, the at least one inorganic pigment material may alsobe combined with a functional filler. The functional filler(s) mayinclude, but not be limited to, carbon fibers, carbon nanotubes,non-platelet clays (such as attapulgite, kyanite, palygorskite,silimanite, or andalucite), fumed silica, boron nitride, cordierite,solid glass microspheres, hollow glass microspheres and the like.According to certain embodiments, the functional fillers may includefinely divided metal oxides, which may comprise at least one ofpyrogenic silicas, arc silicas, low-alkali precipitated silicas, fumedsilica, silicon dioxide aerogels, aluminum oxides, titania, calcia,magnesia, potassia, or mixtures thereof.

In certain embodiments, the functional filler may comprise endothermicfillers such as alumina trihydrate, magnesium carbonate, and otherhydrated inorganic materials including cements, hydrated zinc borate,calcium sulfate (gypsum), magnesium ammonium phosphate, magnesiumhydroxide and any combination thereof. In further embodiments, thefunctional filler(s) may include lithium-containing minerals. In stillfurther embodiments, the functional fillers(s) may include fluxingagents and/or fusing agents.

In certain embodiments, the functional filler may comprise fireretardant fillers such as antimony compounds, magnesium hydroxide,hydrated alumina compounds, borates, carbonates, bicarbonates, inorganichalides, phosphates, sulfates, organic halogens, organic phosphates, orany combination thereof.

The Fire Barrier Layer

Without wishing to be limited by theory, the incorporation of the metaloxide coating on to the individual inorganic pigment particles mayinhibit the formation of Van der Waals forces between the individualinorganic pigment particles. In fire barrier laminates utilizing firebarrier layers comprising at least one inorganic pigment material, theindividual pigment particles comprising the individual inorganic pigmentmaterials are held together by the addition of a resin or adhesive thatprovides cohesion between the individual inorganic pigment particles. Inone embodiment, the fire barrier film consists of multiple layers ofoverlapping inorganic pigment particles encompassed in a resin oradhesive.

In one embodiment the at least one inorganic pigment material isformulated to form a fire barrier (504), the formulation comprises amixture of at least one inorganic pigment material and an adhesive. Toform a fire barrier layer, the mixture is then dissolved in a solvent.In one embodiment, the solvent has a dielectric constant less than 30.In one embodiment, the solvent is selected from the group consisting ofxylene, IPA, acetone, ethyl acetate, toluene and combinations thereof.

It can be readily appreciated that the proportion of the adhesive addedto the at least one inorganic pigment material can affect thefunctionality or efficacy or integrity of the non-fibrous fire-barriercomprising a film of at least one inorganic pigment material. In oneembodiment, the at least one inorganic pigment material may be presentfrom about 25% to about 99% in solid weight of the film, and the balanceof the mixture comprises the adhesive. For example, the adhesive may bepresent in the formulation from about 1% to about 75% in solid weight ofthe film.

In one embodiment, the mixture comprises about 75% at least oneinorganic pigment material and about 25% adhesive in solid content.

In an certain embodiments, the adhesive may be acrylic latex,(meth)acrylic latex, phenolic resins, copolymers of styrene andbutadiene, vinylpyridine, acrylonitrile, copolymers of acrylonitrile andstyrene, vinyl chloride, polyurethane, copolymers of vinyl acetate andethylene, polyamides, silicones, unsaturated polyesters, epoxy resins,polyvinyl esters (such as polyvinylacetate or polyvinylbutyrate latexes)and the like.

In one embodiment, the adhesive is a pressure sensitive adhesive. In oneembodiment, the pressure sensitive adhesive is a silicone pressuresensitive adhesive.

In one embodiment, the pressure sensitive adhesive is dissolved in asolvent. In one embodiment, the solvent has a dielectric constant lessthan 30. In one embodiment, the solvent is selected from the groupconsisting of xylene, IPA, acetone, ethyl acetate, toluene andcombinations thereof.

In one embodiment, the fire-barrier layer (504) is formed by theevaporation of the solvent from the mixture of at least one inorganicpigment and adhesive. The integrity of the fire-barrier layer can beaffected by factors, such as, for example, the ratio of at least oneinorganic pigment to adhesive, the rate of evaporation of the solvent,or the thickness of the fire-barrier layer that is deposited. In oneembodiment, the integrity of the fire-barrier layer is enhanced bychoosing a slowly evaporating solvent.

The fire-barrier layer (504) may include inorganic binders. Withoutlimitation, suitable inorganic binders include colloidal dispersions ofalumina, silica, zirconia, and mixtures thereof. In one embodiment, theinorganic binder provides additional fire retardant and thermalconductive properties. The inorganic binders, if present, may be used inamounts ranging from 0 to about 40 percent by weight, in someembodiments from 0 to about 20 weight percent, based upon the totalweight of the fire-barrier layer. However, the incorporation ofinorganic binder should not be detrimental to the performance of thefire-barrier layer.

Solvents for the inorganic binder, if needed, can include a suitableorganic solvent for the binder utilized. Solution strength of the binderin the solvent (if used) can be determined by conventional methods basedon the binder loading desired and the workability of the binder system(viscosity, solids content, etc.).

The fire-barrier layer (504) may further include a functional filler.The functional filler(s) may include, but not be limited to, carbonfibers, carbon nanotubes, non-platelet clays (such as attapulgite,kyanite, palygorskite, silimanite, or andalucite), fumed silica, boronnitride, cordierite, solid glass microspheres, hollow glass microspheresand the like. According to certain embodiments, the functional fillersmay include finely divided metal oxides, which may comprise at least oneof pyrogenic silicas, arc silicas, low-alkali precipitated silicas,fumed silica, silicon dioxide aerogels, aluminum oxides, titania,calcia, magnesia, potassia, or combinations thereof.

In certain embodiments, the functional filler may comprise endothermicfillers such as alumina trihydrate, magnesium carbonate, and otherhydrated inorganic materials including cements, hydrated zinc borate,calcium sulfate (gypsum), magnesium ammonium phosphate, magnesiumhydroxide, or any combination thereof. In further embodiments, thefunctional filler(s) may include lithium-containing minerals. In stillfurther embodiments, the functional fillers(s) may include fluxingagents and/or fusing agents.

In certain embodiments, the functional filler may comprise fireretardant fillers such as antimony compounds, magnesium hydroxide,hydrated alumina compounds, borates, carbonates, bicarbonates, inorganichalides, phosphates, sulfates, organic halogens, organic phosphates, orany combination thereof.

The functional filler, if present, may be included in the fire barrierlayer in an amount of from 0 to about 40 weight percent, in someembodiments from 0 to about 20 weight percent, based upon the totalweight of the fire barrier layer. However, the incorporation offunctional filler should not be detrimental to the performance of thefire-barrier layer.

The Support Layer

In one embodiment, the support layer (501) provides a flexiblemechanical support to the fire-barrier layer (504) of the present firebarrier laminate. For example, the support layer can isolate the firebarrier layer from the mechanical stresses of handling, installation anduse. Alternatively, the support layer can isolate the fire-barrier layerfrom the mechanical stresses induced by the temperature-induced of thefire retardant film, that may be induced by ambient temperature changes,or, alternatively, by a fire.

In one embodiment, the support layer (501) is constructed from amaterial that is flame resistant. In an alternate embodiment the supportlayer (501) is constructed from a material that is flame retardant. Inan alternate embodiment, the support layer (501) is constructed from amaterial that is both flame resistant and flame retardant.

In one embodiment, the support layer comprises a fibrous layer (502) andan adhesive (503). In an alternate embodiment, the support layercomprises a fibrous layer (502). Any fibrous material where the gapsbetween the fibers are small is suitable for use in the support layer ofthe fire-barrier laminate of the present fire barrier laminate, providedthe fibrous layer (502) does not affect the integrity of the non-fibrousfire barrier layer (504). The fibrous material may consist of woven,non-woven, chopped fibers, or any combination thereof. The fibers mayhave a flat cross-sectional profile, alternatively, a roundcross-sectional profile. The fibers may also comprise twisted fibers ofany cross-sectional profile.

In one embodiment, the fibrous layer (502) is a glass fabric. Any glassfabric that does not affect the integrity of the non-fibrous firebarrier layer (504) is suitable for use in the support layer of thepresent fire-barrier laminate. The glass fabric may be constructed usingwoven, or non-woven fibers. In one embodiment, the support layer isconstructed in a manner that reduces the cross-sectional profile of thefire-barrier laminate. In one embodiment the support layer isconstructed using a glass fabric made from non-twisted fibers with aflat cross-sectional profile.

In one embodiment, the adhesive (503) is a pressure sensitive adhesive.In one embodiment, the pressure sensitive adhesive is a siliconepressure sensitive adhesive.

In one embodiment, the pressure sensitive adhesive is dissolved in asolvent. In one embodiment, the solvent has a dielectric constant lessthan 30. In one embodiment, the solvent is selected from the groupconsisting of xylene, IPA, acetone, ethyl acetate, toluene andcombinations thereof.

The First and Second Film Layers

In one embodiment the first (500) and second (506) film layers areconstructed from polymeric flame propagation resistant films, such asbut not limited to polyesters, polyimides, polyetherketones,polyetheretherketones, polyvinylfluorides, polyamides,polytetrafluoroethylenes, polyaryl sulfones, polyester amides, polyesterimides, polyethersulfones, polyphenylene sulfides, ethylenechlorotrifluoroethylene, combinations thereof, and the like.Commercially available examples of these films are films sold by E.I.DuPont de Nemours & Co. of Wilmington, Del., such as a polyester filmsold under the trade designation MYLAR®, a polyvinylfluoride film soldunder the trade designation TEDLAR®, and a polyimide film sold under thetrade designation KAPTON®, a polyetheretherketone film sold under thetrade designation APTIV® by Victrex, plc. of Lancashire, UK, apolyetheretherketone film sold under the trade designation KFTASPIRE®and an ethylene chlorotrifluoroethylene film sold under the tradedesignation HALAR® by Solvay SA of Brussels, Belgium, or any combinationthereof.

In one embodiment, the first film layer (500) is a polyetheretherketonefilm layer.

In one embodiment, the second film layer (506) is a polyetheretherketonefilm layer.

The first and/or the second film layers may be metalized to minimizemoisture absorption, particularly on the outboard side, but optionallyon the inboard side also.

In certain embodiments, the first and/or the second film layers may havean opaque, low-gloss polymer coating, optionally containing a fireretardant additive. The fire retardant additives may comprise at leastone of antimony compounds, hydrated alumina compounds, borates,carbonates, bicarbonates, inorganic halides, phosphates, sulfates,organic halogens, organic phosphates, or any combination thereof.

Assembly of the Fire Barrier Laminates

In one embodiment, the present fire barrier laminate is constructedaccording to the method comprising the steps of:

-   -   a. obtaining a first film layer (500) having a top and bottom        surface, and coating the top surface of the first film layer        with a support layer (501) that comprises a fibrous layer (502)        and a first adhesive layer (503);    -   b. coating the support layer (501) with a non-fibrous fire        barrier layer (504);    -   c. coating the non-fibrous fire barrier layer (504) with a        second adhesive layer (505), and    -   d. optionally obtaining a second film layer (506) having a top        and bottom surface, and applying the second film layer (506) to        the second adhesive layer (505), such that the bottom surface of        the second film layer (506) is contacted with the second        adhesive layer (505).

In one embodiment, a scrim (507) is laminated to the bottom surface ofthe first film layer (500) using an adhesive (508).

In one embodiment, the present fire barrier laminate is constructedaccording to the method consisting the steps of:

-   -   a. obtaining a second film layer (506) having a top and bottom        surface, and applying a second adhesive layer (505) to the top        surface;    -   b. coating the second adhesive layer (505) with a non-fibrous        fire barrier layer (504);    -   c. coating the non-fibrous fire barrier layer (504) with a        support layer (501) that comprises a fibrous layer (502) and a        first adhesive layer (503); and    -   d. applying a first film layer (500) having a top and bottom        surface to the support layer (501), such that the bottom surface        of the first film layer (500) is contacted with the support        layer (501).

In one embodiment, a scrim (507) is laminated to the top surface of thefirst film layer (500) using an adhesive (508).

In one embodiment, the present fire barrier laminate is constructedaccording to the method consisting the steps of:

-   -   a. obtaining a first film layer (500) having a top and bottom        surface, and coating the top surface of the first film layer        with a support layer (501) that comprises a fibrous layer (502)        and a first adhesive layer (503);    -   b. coating the supporting layer (501) with a non-fibrous fire        barrier layer (504); and    -   c. obtaining a second film layer (506) having a top and bottom        surface, and applying the second film layer (506) to the        non-fibrous fire barrier layer (504), such that the bottom        surface of the second film layer (506) is contacted with the        non-fibrous fire barrier layer (504).

In one embodiment, a scrim (507) is laminated to the bottom surface ofthe first film layer (500) using an adhesive (508).

In one embodiment, the present fire barrier laminate is constructedaccording to the method consisting the steps of:

-   -   a. obtaining a second film layer (506) having a top and bottom        surface, and applying a non-fibrous fire barrier layer (504) to        the top surface;    -   b. coating the non-fibrous fire barrier layer (504) with a        support layer (501) that comprises a fibrous layer (502) and a        first adhesive layer (503); and    -   c. applying a first film layer (500) having a top and bottom        surface to the support layer (501), such that the bottom surface        of the first film layer (500) is contacted with the support        layer (501).

In one embodiment, a scrim (507) is laminated to the top surface of thefirst film layer (500) using an adhesive (508).

In one embodiment, the present fire barrier laminate is constructedaccording to the method consisting the steps of:

-   -   a. obtaining a first film layer (500) having a top and bottom        surface, and coating the top surface of the first film layer        with a fibrous layer (502);    -   b. coating the fibrous layer (502) with a non-fibrous fire        barrier layer (504); and    -   c. obtaining a second film layer (506) having a top and bottom        surface, and applying the second film layer (506) to the        non-fibrous fire barrier layer (504), such that the bottom        surface of the second film layer (506) is contacted with the        non-fibrous fire barrier layer (504).

In one embodiment, a scrim (507) is laminated to the bottom surface ofthe first film layer (500) using an adhesive (508).

In one embodiment, the present fire barrier laminate is constructedaccording to the method consisting the steps of:

-   -   a. obtaining a second film layer (506) having a top and bottom        surface, and applying a non-fibrous fire barrier layer (504) to        the top surface;    -   b. applying a fibrous layer (502) to the non-fibrous fire        barrier layer (504); and    -   c. applying a first film layer (500) having a top and bottom        surface to the support layer (501), such that the bottom surface        of the first film layer (500) is contacted with the fibrous        layer (502).

In one embodiment, a scrim (507) is laminated to the top surface of thefirst film layer (500) using an adhesive (508).

In one embodiment, the present fire barrier laminate is constructedaccording to the method consisting the steps of:

-   -   a. obtaining a first film layer (500) having a top and bottom        surface, and coating the top surface of the first film layer        with a fibrous layer (502);    -   b. coating the fibrous layer (502) with a non-fibrous fire        barrier layer (504);    -   c. coating the non-fibrous fire barrier layer (504) with a third        adhesive layer (510); and    -   d. obtaining a second film layer (506) having a top and bottom        surface, and applying the second film layer (506) to the third        adhesive layer (510), such that the bottom surface of the second        film layer (506) is contacted with the third adhesive layer        (510).

In one embodiment, a scrim (507) is laminated to the bottom surface ofthe first film layer (500) using an adhesive (508).

In one embodiment, the present fire barrier laminate is constructedaccording to the method consisting the steps of:

-   -   a. obtaining a second film layer (506) having a top and bottom        surface, and applying a third adhesive layer (510) to the top        surface;    -   b. coating the third adhesive layer (510) with a non-fibrous        fire barrier layer (504);    -   c. applying a fibrous layer (502) to the non-fibrous fire        barrier layer (504); and    -   d. applying a first film layer (500) having a top and bottom        surface to the support layer (501), such that the bottom surface        of the first film layer (500) is contacted with the fibrous        layer (502).

In one embodiment, a scrim (507) is laminated to the top surface of thefirst film layer (500) using an adhesive (508).

In one embodiment, the present fire barrier laminate is constructedaccording to the method consisting the steps of:

-   -   a. obtaining a first film layer (500) having a top and bottom        surface, and coating the top surface of the first film layer        with a first adhesive layer (503);    -   b. coating the first adhesive layer (503) with a fibrous layer        (502);    -   c. coating the fibrous layer (502) with a non-fibrous fire        barrier layer (504);    -   d. coating the non-fibrous fire barrier layer (504) with a        second adhesive layer (505); and    -   e. obtaining a second film layer (506) having a top and bottom        surface, and applying the second film layer (506) to the second        adhesive layer (505), such that the bottom surface of the second        film layer (506) is contacted with the second adhesive layer        (505).

In one embodiment, a scrim (507) is laminated to the bottom surface ofthe first film layer (500) using an adhesive (508).

In one embodiment, the present fire barrier laminate is constructedaccording to the method consisting the steps of:

-   -   a. obtaining a second film layer (506) having a top and bottom        surface, and applying a second adhesive layer (505) to the top        surface;    -   b. coating the second adhesive layer (505) with a non-fibrous        fire barrier layer (504);    -   c. coating the non-fibrous fire barrier layer (504) with a        fibrous layer (502);    -   d. coating the fibrous layer (502) with a first adhesive layer        (503); and    -   e. applying a first film layer (500) having a top and bottom        surface to first adhesive layer (503), such that the bottom        surface of the first film layer (500) is contacted with first        adhesive layer (503).

In one embodiment, a scrim (507) is laminated to the top surface of thefirst film layer (500) using an adhesive (508).

In one embodiment, the present fire barrier laminate is constructedaccording to the method consisting the steps of:

-   -   a. obtaining a first film layer (500) having a top and bottom        surface, and coating the top surface of the first film layer        with a first adhesive layer (503);    -   b. coating the first adhesive layer (503) with a fibrous layer        (502);    -   c. coating the fibrous layer (502) with a non-fibrous fire        barrier layer (504); and    -   d. obtaining a second film layer (506) having a top and bottom        surface, and applying the second film layer (506) to the        non-fibrous fire barrier layer (504), such that the bottom        surface of the second film layer (506) is contacted with        non-fibrous fire barrier layer (504).

In one embodiment, a scrim (507) is laminated to the bottom surface ofthe first film layer (500) using an adhesive (508).

In one embodiment, the present fire barrier laminate is constructedaccording to the method consisting the steps of:

-   -   a. obtaining a second film layer (506) having a top and bottom        surface, and applying a non-fibrous fire barrier layer (504) to        the top surface;    -   b. applying a fibrous layer (502) to the non-fibrous fire        barrier layer (504);    -   c. coating the fibrous layer (502) with a first adhesive layer        (503); and    -   d. applying a first film layer (500) having a top and bottom        surface to first adhesive layer (503), such that the bottom        surface of the first film layer (500) is contacted with first        adhesive layer (503).

In one embodiment, a scrim (507) is laminated to the top surface of thefirst film layer (500) using an adhesive (508).

The present fire barrier laminate is further illustrated, but notlimited by, the following examples.

EXAMPLES Example 1

Sample 1 comprised a fire barrier layer containing suspended exfoliatedvermiculite flakes, silicone binder and water. The fire barrier layerwas applied to a polyetheretherketone (PEEK) film, which had previouslybeen coated with a silicone adhesive and allowed to dry. Separately, asecond PEEK film was laminated to a nylon scrim using a siliconelaminating adhesive. The scrim side of the laminate was laminated to thefire barrier layer side of the fire barrier layer-coated PEEK film toform a fire barrier laminate. A heat seal adhesive was then applied tothe face of the fire barrier laminate opposite the second PEEK film. Thefire barrier laminate final construction had a basis weight of 97 gsmand passed the test protocols of 14 C.F.R.

25.856(a) and (b), described below.

Sample 2 comprised a fire barrier layer containing suspended exfoliatedvermiculite flakes and water. The fire barrier layer was applied to apolyetheretherketone (PEEK) film which had previously been coated with amodified natural rubber adhesive and allowed to dry. Separately, asecond PEEK film was laminated to a nylon scrim using a poly(amide)laminating adhesive. The scrim side of the laminate was laminated to thefire barrier layer side of the fire barrier layer-coated PEEK film toform a fire barrier laminate. A heat seal adhesive was then applied tothe face of the fire barrier laminate opposite the second PEEK film anda fiberglass scrim was incorporated onto the heat seal adhesive-coatedface. The fire barrier laminate final construction had a basis weight of90 gsm and passed the test protocols of 14 C.F.R.

25.856(a) and (b), described below.

Sample 3 comprised a fire barrier layer containing suspended exfoliatedvermiculite flakes, silicone binder and water. The fire barrier layerwas applied to a polyetheretherketone (PEEK) film which had previouslybeen coated with a modified natural rubber adhesive and allowed to dry.Separately, a second PEEK film was laminated to a nylon scrim using apoly(amide) laminating adhesive. The scrim side of the laminate waslaminated to the fire barrier layer side of the fire barrierlayer-coated PEEK film to form a fire barrier laminate. A heat sealadhesive was then applied to the face of the fire barrier laminateopposite the second PEEK film. The fire barrier laminate finalconstruction had a basis weight of 103 gsm and passed the test protocolsof 14 C.F.R.

25.856(a) and (b), described below.

Sample 4 comprised a fire barrier layer containing suspended exfoliatedvermiculite flakes, silicone binder and water. The fire barrier layerwas applied to a polyetheretherketone (PEEK) film which had previouslybeen coated with a modified natural rubber adhesive and allowed to dry.Separately, an ethylene chlorotrifluoroethylene (ECTFE) film waslaminated to a nylon scrim using a silicone laminating adhesive. Thescrim side of the laminate was laminated to the fire barrier layer sideof the fire barrier layer-coated PEEK film to form a fire barrierlaminate. A heat seal adhesive was then applied to the external face ofthe ECTFE film. The fire barrier laminate final construction had a basisweight of 95 gsm and passed the test protocols of 14 C.F.R.

25.856(a) and (b), described below.

Sample 5 comprised a fire barrier layer containing suspended exfoliatedvermiculite flakes and water. The fire barrier layer was applied to apolyetheretherketone (PEEK) film which had previously been coated with amodified natural rubber adhesive and allowed to dry. Separately, asecond PEEK film was laminated to a nylon scrim using a siliconelaminating adhesive. The scrim side of the laminate was laminated to thefire barrier layer side of the fire barrier layer-coated PEEK film toform a fire barrier laminate. A heat seal adhesive was then applied tothe face of the fire barrier laminate opposite the second PEEK film anda nylon scrim was incorporated onto the heat seal adhesive-coated face.The fire barrier laminate final construction had a basis weight of 105gsm and passed the test protocols of 14 C.F.R.

25.856(a) and (b), described below.

Samples containing a fire barrier laminate comprising at least oneinorganic pigment material were also constructed and their fireretardant properties were tested, either using the FAA protocoldescribed in paragraphs [0256] to [0312] (“FAA”), or using acorresponding protocol that is analogous to the protocol of 14 C.F.R.

25.856(a) and (b), Appendix F, Parts VI and VII (“Analogous Protocol”).A summary of the fire barrier laminates tested, the protocols used, andthe results may be found in Table 1.

TABLE 1 Summary of Samples Comprising Various Embodiments of FireBarrier Laminates Support Layer (501) Non-fibrous Fire Barrier LayerFirst (504) Second First Film Adhesive Fibrous Inorganic Second FilmSample Scrim Adhesive Layer Layer Layer Platelet/ Adhesive Layer No(507) (508) (500) (503) (503) Pigment Adhesive Filler Layer (505) (506)Tested Result 6 Nylon Heat seal PEEK silicone glass 75% silicone Nonesilicone PEEK Analogous Pass scrim adhesive fabric Pigment 1 adhesiveadhesive Protocol to 25% adhesive in solid content 7 Nylon Heat sealPEEK silicone glass 75% silicone None silicone PEEK Analogous Pass scrimadhesive fabric Pigment 2 adhesive adhesive Protocol to 25% adhesive insolid content 8 Nylon Heat seal PEEK silicone glass 75% silicone Nonesilicone PEEK Analogous Pass scrim adhesive fabric Pigment 3 adhesiveadhesive Protocol to 25% adhesive in solid content 9 Nylon Heat sealPEEK silicone glass 75% silicone None None None Analogous Pass scrimadhesive fabric Pigment 1 adhesive Protocol to 25% adhesive in solidcontent 10 Nylon Heat seal PEEK silicone glass 75% silicone None NoneNone Analogous Pass scrim adhesive fabric Pigment 2 adhesive Protocol to25% adhesive in solid content 11 Nylon Heat seal PEEK silicone glass 75%silicone None None None Analogous Pass scrim adhesive fabric Pigment 3adhesive Protocol to 25% adhesive in solid content 12 Nylon Heat sealPEEK silicone glass 75% silicone None silicone PEEK Analogous Pass scrimadhesive fabric Pigment 3 adhesive adhesive Protocol to 25% adhesive insolid content 13 Nylon Heat seal PEEK silicone glass 75% silicone NoneNone None Analogous Pass scrim adhesive fabric Pigment 4 adhesiveProtocol to 25% adhesive in solid content 14 Nylon Heat seal PEEKsilicone glass 75% silicone None None None Analogous Pass scrim adhesivefabric Pigment 5 adhesive Protocol to 25% adhesive in solid content 15Nylon Heat seal PEEK silicone glass 75% silicone None None NoneAnalogous Pass scrim adhesive fabric Pigment 6 adhesive Protocol to 25%adhesive in solid content 16 Nylon Heat seal PEEK silicone glass 75%silicone None None None Analogous Pass scrim adhesive fabric Pigment 7adhesive Protocol to 25% adhesive in solid content 17 Nylon Heat sealPEEK silicone glass 75% silicone None None None Analogous Pass scrimadhesive fabric Pigment 8 adhesive Protocol to 25% adhesive in solidcontent 18 Nylon Heat seal PEEK silicone glass 75% silicone None NoneNone Analogous Pass scrim adhesive fabric Pigment 9 adhesive Protocol to25% adhesive in solid content 19 Nylon Heat seal PEEK silicone glass 75%silicone None None None Analogous Pass scrim adhesive fabric Pigmentadhesive Protocol 10 to 25% adhesive in solid content 20 Nylon Heat sealPEEK silicone glass 75% silicone None None None Analogous Fail scrimadhesive fabric Pigment adhesive Protocol 11 to 25% adhesive in solidcontent 21 Nylon Heat seal PEEK silicone glass 75% silicone Nonesilicone PEEK FAA Pass scrim adhesive fabric Pigment 3 adhesive adhesiveto 25% adhesive in solid content 22 Nylon Heat seal PEEK silicone glass37.5% silicone None None None Analogous Pass scrim adhesive fabricPigment 3, adhesive Protocol 37.5% of Pigment 8 to 25% adhesive in solidcontent 23 Nylon Heat seal PEEK silicone glass 37.5% silicone None NoneNone Analogous Pass scrim adhesive fabric Pigment 3, adhesive Protocol37.5% Pigment 5 to 25% adhesive in solid content 24 Nylon Heat seal PEEKsilicone glass 75% silicone glass silicone PEEK No scrim adhesive fabricPigment 3 adhesive bubbles adhesive to 25% adhesive in solid content 25Nylon Heat seal PEEK silicone glass 75% silicone glass silicone PEEK Noscrim adhesive fabric Pigment 3 adhesive spheres adhesive to 25%adhesive in solid content 26 Nylon Heat seal PEEK silicone glass 75%silicone carbon silicone PEEK No scrim adhesive fabric Pigment 3adhesive nanotubes adhesive to 25% adhesive in solid content

Sample 6 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film and a heatseal, and the opposite side coated with silicone adhesive diluted intosolvent, applied by reverse roll coating and laminated with glassfabric. A fire barrier layer comprising 75% solid of a silver coloredpigment comprising TiO₂-coated mica platelets, with a particle sizeranging between 10-60 μm (chemical composition of 66-74% mica, 26-33%TiO₂ and 0-1% SnO₂) (Pigment 1) to 25% solid silicone adhesive dilutedinto solvent was applied to the glass fabric layer by gravure rollcoating in two passes. A coating of silicone adhesive diluted intosolvent was applied to the fire barrier layer by reverse roll coatingand laminated with a second PEEK film, reaching a total weight of 2.99osy.

Sample 7 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by reverse roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid of a weather resistant silver coloredpigment comprising TiO₂-coated mica platelets, with a particle sizeranging between 4-40 μm (chemical composition of 66-73% mica, 27-32%TiO₂ and 0-2% SnO₂) (Pigment 2) to 25% solid silicone adhesive dilutedinto solvent was applied to the glass fabric layer by gravure rollcoating in two passes. A coating of silicone adhesive diluted intosolvent was applied to the fire barrier layer by reverse roll coatingand laminated with a second PEEK film, reaching a total weight of 2.95osy.

Sample 8 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid of a silver colored pigmentcomprising TiO₂-coated mica platelets, with a particle size rangingbetween 15-70 μm (chemical composition of 68-77% mica, 23-31% TiO₂, lessthan 1% chromium (HI) and less than 1% SnO₂) (Pigment 3) to 25% solidsilicone adhesive diluted into solvent was applied to the glass fabriclayer by gravure roll coating in two passes. A coating of siliconeadhesive diluted into solvent was applied to the fire barrier layer bygravure roll coating and laminated with a second PEEK film, reaching atotal weight of 3.02 osy.

Sample 9 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid Pigment 1 to 25% solid siliconeadhesive diluted into solvent was applied to the glass fabric layer bygravure roll coating in two passes.

Sample 10 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid Pigment 2 to 25% solid siliconeadhesive diluted into solvent was applied to the glass fabric layer bygravure roll coating in two passes.

Sample 11 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid Pigment 3 to 25% solid siliconeadhesive diluted into solvent was applied to the glass fabric layer bygravure roll coating in two passes.

Sample 12 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid Pigment 3 to 25% solid siliconeadhesive diluted into solvent was applied to the glass fabric layer bygravure roll coating in two passes. A coating of silicone adhesivediluted into solvent was applied to the fire barrier layer by gravureroll coating and laminated with a second PEEK film, reaching a totalweight of 3.05 osy.

Sample 13 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid of a pigment comprising TiO₂-coatedmica platelets, with a particle size ranging between 10-50 μm (chemicalcomposition of 66-74% mica, 26-32% TiO₂, less than 0.5% chromium (III)and less than 1% SnO₂) (Pigment 4) to 25% solid silicone adhesivediluted into solvent was applied to the glass fabric layer by gravureroll coating in two passes.

Sample 14 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid of a silver colored weather resistantpigment comprising TiO₂-coated mica platelets, with a particle sizeranging between 1-15 μm (chemical composition of 42-54% mica, 46-47%TiO₂, less than 0.5% chromium (III) and less than 1% SnO₂) (Pigment 5)to 25% solid silicone adhesive diluted into solvent was applied to theglass fabric layer by gravure roll coating in two passes.

Sample 15 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid of a silver colored pigmentcomprising TiO₂-coated mica platelets, with a particle size rangingbetween 10-60 μm (chemical composition of 69-73% mica, 27-31% TiO₂, and0-1% SnO₂) (Pigment 6) to 25% solid silicone adhesive diluted intosolvent was applied to the glass fabric layer by gravure roll coating intwo passes.

Sample 16 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid of a green pigment comprisingTiO₂-coated mica platelets, with a particle size ranging between 10-60μm (chemical composition 41-50% mica, 50-58% TiO₂ and 0-1% SnO₂)(Pigment 7) to 25% solid silicone adhesive diluted into solvent wasapplied to the glass fabric layer by gravure roll coating in two passes.

Sample 17 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid of a green colored pigment comprisingTiO₂-coated mica platelets, with a particle size ranging between 15-70μm (chemical composition of 45-59% mica, and 41-54% TiO₂ (Pigment 8) to25% solid silicone adhesive diluted into solvent was applied to theglass fabric layer by gravure roll coating in two passes.

Sample 18 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid of a copper colored pigmentcomprising Fe₂O₃-coated mica platelets, with a particle size rangingbetween 10-70 μm (chemical composition of 55-66% mica, and 34-45% Fe₂O₃(Pigment 9) to 25% solid silicone adhesive diluted into solvent wasapplied to the glass fabric layer by gravure roll coating in two passes.

Sample 19 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid of a weather resistant pigmentcomprising TiO₂-coated synthetic mica platelets, with a particle sizeranging between 9-41 μm (chemical composition of 20-30% TiO₂) (Pigment10) to 25% solid silicone adhesive diluted into solvent was applied tothe glass fabric layer by gravure roll coating in two passes.

Sample 20 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid of a silver colored pigmentcomprising TiO₂ coated borosilicate platelets, with a particle sizeranging between 30-100 μm (chemical composition of 5-15% TiO₂) (Pigment11) to 25% solid silicone adhesive diluted into solvent was applied tothe glass fabric layer by gravure roll coating in two passes.

Sample 21 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 75% solid Pigment 3 to 25% solid siliconeadhesive diluted into solvent was applied to the glass fabric layer bygravure roll coating in two passes. A coating of silicone adhesivediluted into solvent was applied to the fire barrier layer by gravureroll coating and laminated with a second PEEK film, reaching a totalweight of 2.95 osy.

Sample 22 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 37.5 solid Pigment 3, and 37.5 solid Pigment 8to 25% solid silicone adhesive diluted into solvent was applied to theglass fabric layer by gravure roll coating in two passes.

Sample 23 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 37.5 solid Pigment 3, and 37.5 solid Pigment 5to 25% solid silicone adhesive diluted into solvent was applied to theglass fabric layer by gravure roll coating in two passes.

Sample 24 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 70% solid Pigment 3 to 25% solid siliconeadhesive diluted into solvent and a filler comprising 5% solid glassbubbles was applied to the glass fabric layer by gravure roll coating intwo passes.

Sample 25 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric. A firebarrier layer comprising 70% solid Pigment 3 to 20% solid siliconeadhesive diluted into solvent and a filler comprising 10% solid glassspheres was applied to the glass fabric layer by gravure roll coating intwo passes.

Sample 26 comprised a polyetheretherketone (PEEK) film, which had beenlaminated with a scrim layer on one side of the PEEK film, and theopposite side coated with silicone adhesive diluted into solvent,applied by gravure roll coating and laminated with glass fabric.

A fire barrier layer comprising 73% Pigment 3 to 25% silicone adhesivediluted into solvent and a filler comprising 2% carbon nanotubes wasapplied to the glass fabric layer by gravure roll coating in two passes.

For testing according to 14 C.F.R.

25.856(a), the fire barrier laminate of each of the Samples 1-5 wereused to encapsulate two (2) 1 inch layers of 0.34 pcf MICROLITE AA®premium fiberglass insulation with LAMAGUARD® 131MD companion polymerfilm. The fire barrier laminate was heat sealed in order to encapsulatethe fiberglass insulation.

For testing according to 14 C.F.R.

25.856(b) the fire barrier laminate of each of the Samples 1-5 were usedto encapsulate one (1) 1 inch layer of 0.34 pcf MICROLITE AA® premiumfiberglass insulation with LAMAGUARD® 131MD companion polymer film. Thefire barrier laminate was mechanically sealed using staples in order toencapsulate the fiberglass insulation.

The ability of samples of the present fire barrier laminate to resistthe absorption of water was also tested. The protocols utilized were asfollows: In one test, samples of the fire barrier laminates wereweighed, then completely immersed in 23° C. water for 72 h. After thistime, the samples were re-weighed. The results were compared to theAirbus Industrie Standard AIMS04-18-000 clause 4.2.2.8.6, requiring theincrease in weight to exceed 6% following immersion.

In another test, samples of the fire barrier laminates were weighed,then completely immersed in 23° C. water for 24 h, followed by completeimmersion in 40° C. water for 1 h, followed by complete immersion in 23°C. water for 24 h. After this time, the samples were re-weighed. Theresults were compared to the Airbus Industrie Standard AIMS04-18-000clause 4.2.2.8.7, requiring the increase in weight to exceed 6%following immersion.

In another test, water absorption, measured by capillary rise wastested. The distance of water absorbed into samples of the fire barrierlaminates by capillary action was measured in the transverse andlongitudinal direction. The results were compared to the ISO9073-6standard, requiring that no water be absorbed by capillary action after60 s of immersion.

The water absorption observed did not exceed the permitted levels in anyof Samples 6-26, under the conditions tested.

Test Protocols Set Forth in 14 C.F.R. 25.856(a) and (b), Appendix F,Parts VI and VII

The fire barrier film laminate-protected thermal/acoustic insulationblankets described above were tested according to the protocols of 14C.F.R.

25.856(a) and (b), Appendix F, Parts VI and VII, which are incorporatedherein in their entirety, as if fully written out below.

14 C.F.R. §25.856(a) and (b) provide in pertinent part:

§25.856 Thermal/Acoustic insulation materials.

(a) Thermal/acoustic insulation material installed in the fuselage mustmeet the flame propagation test requirements of part VI of Appendix F tothis part, or other approved equivalent test requirements.

(b) For airplanes with a passenger capacity of 20 or greater,thermal/acoustic insulation materials (including the means of fasteningthe materials to the fuselage) installed in the lower half of theairplane fuselage must meet the flame penetration resistance testrequirements of part VII of Appendix F to this part, or other approvedequivalent test requirements.

Appendix F Part VI provides, in pertinent part:

Part VI—Test Method to Determine the Flammability and Flame PropagationCharacteristics of Thermal Acoustic Insulation Materials

Use this test method to evaluate the flammability and flame propagationcharacteristics of thermal/acoustic insulation when exposed to both aradiant heat source and a flame.

(a) Definitions.

“Flame propagation” means the furthest distance of the propagation ofvisible flame towards the far end of the test specimen, measured fromthe midpoint of the ignition source flame. Measure this distance afterinitially applying the ignition source and before all flame on the testspecimen is extinguished. The measurement is not a determination of burnlength made after the test.

“Radiant heat source” means an electric or air propane panel.

“Thermal/acoustic insulation” means a material or system of materialsused to provide thermal and/or acoustic protection. Examples includefiberglass or other batting material encapsulated by a film covering andfoams.

“Zero point” means the point of application of the pilot burner to thetest specimen.

(b) Test apparatus.

(4) Pilot Burner. The pilot burner used to ignite the specimen must be aBemzomatic™ commercial propane venturi torch with an axially symmetricburner tip and a propane supply tube with an orifice diameter of 0.006inches (0.15 mm). The length of the burner tube must be 2⅞ inches (71mm). The propane flow must be adjusted via gas pressure through anin-line regulator to produce a blue inner cone length of ¾ inch (19 mm).A ¾ inch (19 mm) guide (such as a thin strip of metal) may be solderedto the top of the burner to aid in setting the flame height. The overallflame length must be approximately 5 inches long (127 mm). Provide a wayto move the burner out of the ignition position so that the flame ishorizontal and at least 2 inches (50 mm) above the specimen plane.

(5) Thermocouples. Install a 24 American Wire Gauge (AWG) Type K(Chromel-Alumel) thermocouple in the test chamber for temperaturemonitoring. Insert it into the chamber through a small hole drilledthrough the back of the chamber. Place the thermocouple so that itextends 11 inches (279 mm) out from the back of the chamber wall, 11½inches (292 mm) from the right side of the chamber wall, and is 2 inches(51 mm) below the radiant panel. The use of other thermocouples isoptional.

(6) calorimeter. The calorimeter must be a one-inch cylindricalwater-cooled, total heat flux density, foil type Gardon Gage that has arange of 0 to 5 BTU/ft²-second (0 to 5.7 Watts/cm²).

(c) Test specimens.

(1) Specimen preparation. Prepare and test a minimum of three testspecimens. If an oriented film cover material is used, prepare and testboth the warp and fill directions.

(2) Construction. Test specimens must include all materials used inconstruction of the insulation (including batting, film, scrim, tapeetc.). Cut a piece of core material such as foam or fiberglass, and cuta piece of film cover material (if used) large enough to cover the corematerial. Heat sealing is the preferred method of preparing fiberglasssamples, since they can be made without compressing the fiberglass (“boxsample”). Cover materials that are not heat sealable may be stapled,sewn, or taped as long as the cover material is over-cut enough to bedrawn down the sides without compressing the core material. Thefastening means should be as continuous as possible along the length ofthe seams. The specimen thickness must be of the same thickness asinstalled in the airplane.

(3) Specimen Dimensions. To facilitate proper placement of specimens inthe sliding platform housing, cut non-rigid core materials, such asfiberglass, 12½ inches (318 mm) wide by 23 inches (584 mm) long. Cutrigid materials, such as foam, 11½±¼ inches (292 mm±6 mm) wide by 23inches (584 mm) long in order to fit properly in the sliding platformhousing and provide a flat, exposed surface equal to the opening in thehousing.

(d) Specimen conditioning. Condition the test specimens at 70±5° F.(21°±2° C.) and 55%±10% relative humidity, for a minimum of 24 hoursprior to testing.

(f) Test Procedure.

(1) Ignite the pilot burner. Ensure that it is at least 2 inches (51 mm)above the top of the platform. The burner must not contact the specimenuntil the test begins.

(2) Place the test specimen in the sliding platform holder. Ensure thatthe test sample surface is level with the top of the platform. At “zero”point, the specimen surface must be 7½ inches±⅛inch (191 mm±3) below theradiant panel.

(3) Place the retaining/securing frame over the test specimen. It may benecessary (due to compression) to adjust the sample (up or down) inorder to maintain the distance from the sample to the radiant panel (7½inches±⅛ inch (191 mm±3) at “zero” position). With film/fiberglassassemblies, it is critical to make a slit in the film cover to purge anyair inside. This allows the operator to maintain the proper testspecimen position (level with the top of the platform) and to allowventilation of gases during testing. A longitudinal slit, approximately2 inches (51 mm) in length, must be centered 3 inches±½ inch (76 mm±13mm) from the left flange of the securing frame. A utility knife isacceptable for slitting the film cover.

(4) Immediately push the sliding platform into the chamber and close thebottom door.

(5) Bring the pilot burner flame into contact with the center of thespecimen at the “zero” point and simultaneously start the timer. Thepilot burner must be at a 27° angle with the sample and be approximately½ inch (12 mm) above the sample. A stop . . . allows the operator toposition the burner correctly each time.

(6) Leave the burner in position for 15 seconds and then remove to aposition at least 2 inches (51 mm) above the specimen.

(g) Report.

(1) Identify and describe the test specimen.

(2) Report any shrinkage or melting of the test specimen.

(3) Report the flame propagation distance. If this distance is less than2 inches, report this as a pass (no measurement required).

(4) Report the after-flame time.

(h) Requirements.

(1) There must be no flame propagation beyond 2 inches (51 mm) to theleft of the centerline of the pilot flame application.

(2) The flame time after removal of the pilot burner may not exceed 3seconds on any specimen.

Appendix F Part VII provides, in pertinent part:

Part VII—Test Method to Determine the Burnthrough Resistance ofThermal/Acoustic Insulation Materials

Use the following test method to evaluate the burnthrough resistancecharacteristics of aircraft thermal/acoustic insulation materials whenexposed to a high intensity open flame.

(a) Definitions.

“Burnthrough time” means the time, in seconds, for the burner flame topenetrate the test specimen, and/or the time required for the heat fluxto reach 2.0 Btu/ft² sec (2.27 W/cm²) on the inboard side, at a distanceof 12 inches (30.5 cm) from the front surface of the insulation blankettest frame, whichever is sooner. The burnthrough time is measured at theinboard side of each of the insulation blanket specimens.

“Insulation blanket specimen” means one of two specimens positioned ineither side of the test rig, at an angle of 30° with respect tovertical.

“Specimen set” means two insulation blanket specimens. Both specimensmust represent the same production insulation blanket construction andmaterials, proportioned to correspond to the specimen size.

(b) Apparatus.

(3) Calibration rig and equipment.

(i) Construct individual calibration rigs to incorporate a calorimeterand thermocouple rake for the measurement of heat flux and temperature.Position the calibration rigs to allow movement of the burner from thetest rig position to either the heat flux or temperature position withminimal difficulty.

(ii) Calorimeter. The calorimeter must be a total heat flux, foil typeGardon Gage of an appropriate range such as 0-20 Btu/ft²-sec (0-22.7W/cm²), accurate to ±3% of the indicated reading. The heat fluxcalibration method must be in accordance with paragraph VI(b)(7) of thisappendix.

(iv) Thermocouples. Provide seven ⅛-inch (3.2 mm) ceramic packed, metalsheathed, type K (Chromel-alumel), grounded junction thermocouples witha nominal 24 American Wire Gauge (AWG) size conductor for calibration.Attach the thermocouples to a steel angle bracket to form a thermocouplerake for placement in the calibration rig during burner calibration.

(5) Backface calorimeters. Mount two total heat flux Gardon typecalorimeters behind the insulation test specimens on the back side(cold) area of the test specimen mounting frame. Position thecalorimeters along the same plane as the burner cone centerline, at adistance of 4 inches (102 mm) from the vertical centerline of the testframe.

(i) The calorimeters must be a total heat flux, foil type Gardon Gage ofan appropriate range such as 0-5 Btu/ft²-scc (0-5.7 W/cm²), accurate to±3% of the indicated reading. The heat flux calibration method mustcomply with paragraph VI(b)(7) of this appendix.

(6) Instrumentation. Provide a recording potentiometer or other suitablecalibrated instrument with an appropriate range to measure and recordthe outputs of the calorimeter and the thermocouples.

(7) Timing device. Provide a stopwatch or other device, accurate to ±1%,to measure the time of application of the burner flame and burnthroughtime.

(c) Test Specimens.

(1) Specimen preparation. Prepare a minimum of three specimen sets ofthe same construction and configuration for testing.

(2) Insulation blanket test specimen.

(i) For batt-type materials such as fiberglass, the constructed,finished blanket specimen assemblies must be 32 inches wide by 36 incheslong (81.3 by 91.4 cm), exclusive of heat sealed film edges.

(3) Construction. Make each of the specimens tested using the principalcomponents (i.e., insulation, fire barrier material if used, andmoisture barrier film) and assembly processes (representative seams andclosures).

(i) Fire barrier material. If the insulation blanket is constructed witha fire barrier material, place the fire barrier material in a mannerreflective of the installed arrangement. For example, if the materialwill be placed on the outboard side of the insulation material, insidethe moisture film, place it the same way in the test specimen.

(v) Conditioning. Condition the specimens at 70°±5° F. (21°±2° C.) and55%±10% relative humidity for a minimum of 24 hours prior to testing.

(f) Test procedure.

(1) Secure the two insulation blanket test specimens to the test frame.The insulation blankets should be attached to the test rig centervertical former using four spring clamps . . . (according to thecriteria of paragraph (c)(4) or (c)(4)(i) of this part of thisappendix).

(2) Ensure that the vertical plane of the burner cone is at a distanceof 4±0.125 inch (102±3 mm) from the outer surface of the horizontalstringers of the test specimen frame, and that the burner and test frameare both situated at a 30° angle with respect to vertical.

(3) When ready to begin the test, direct the burner away from the testposition to the warm-up position so that the flame will not impinge onthe specimens prematurely. Turn on and light the burner and allow it tostabilize for 2 minutes.

(4) To begin the test, rotate the burner into the test position andsimultaneously start the timing device.

(5) Expose the test specimens to the burner flame for 4 minutes and thenturn off the burner. Immediately rotate the burner out of the testposition.

(6) Determine (where applicable) the burnthrough time, or the point atwhich the heat flux exceeds 2.0 Btu/ft²-sec (2.27 W/cm²).

(g) Report.

(1) Identify and describe the specimen being tested.

(2) Report the number of insulation blanket specimens tested.

(3) Report the burnthrough time (if any), and the maximum heat flux onthe back face of the insulation blanket test specimen, and the time atwhich the maximum occurred.

(h) Requirements.

(1) Each of the two insulation blanket test specimens must not allowfire or flame penetration in less than 4 minutes.

(2) Each of the two insulation blanket test specimens must not allowmore than 2.0 Btu/ft²-sec (2.27 W/cm²) on the cold side of theinsulation specimens at a point 12 inches (30.5 cm) from the face of thetest rig.

Although the various aspects of the fire barrier laminate have beenillustrated above by reference to examples and preferred embodiments, itwill be appreciated that the scope of the present subject matter isdefined not by the foregoing description but by the following claimsproperly construed under principles of patent law.

What is claimed is:
 1. A thermal acoustic insulation system that passesthe flame propagation and burnthrough resistance test protocols of 14C.F.R. §25.856(a) and (b), Appendix F, Parts VI and VII, comprising atleast one insulating layer disposed within a covering of: (i) anexteriorly facing fire barrier laminate comprising: (a) a first filmlayer; (b) a support layer on top of the first film layer; (c) anon-fibrous fire barrier layer on top of the support layer; and (d)optionally, a second film layer on top of the non-fibrous fire barrierlayer; wherein the non-fibrous fire barrier layer comprises at least oneinorganic pigment material, wherein the at least one inorganic pigmentmaterial comprises mica; and (ii) an interiorly facing inboard coverfilm.
 2. The thermal acoustic insulation system of claim 1, wherein theinteriorly facing inboard cover film is the same as the exteriorlyfacing fire barrier laminate.
 3. The thermal acoustic insulation systemof claim 1, wherein the interiorly facing inboard cover film consistsessentially of a polymer film.
 4. The thermal acoustic insulation systemof claim 1, wherein the exteriorly facing fire barrier laminate and theinteriorly facing inboard cover film are sealed with an adhesive topartially or substantially totally envelop or encapsulate the at leastone insulating layer.
 5. A thermal acoustic insulation system thatpasses the flame propagation and burnthrough resistance test protocolsof 14 C.F.R. §25.856(a) and (b), Appendix F, Parts VI and VII,comprising at least one insulating layer disposed within a covering of:(i) an exteriorly facing fire barrier laminate comprising: (a) a firstfilm layer; (b) a non-fibrous fire barrier layer proximate to the firstfilm layer, the non-fibrous fire barrier layer comprising at least oneinorganic pigment material; (c) a support layer between the first filmlayer and the non-fibrous fire barrier layer; and (d) optionally, asecond film layer on top of the non-fibrous fire barrier layer; and (ii)an interiorly facing inboard cover film.
 6. The thermal acousticinsulation system of claim 5, wherein the interiorly facing inboardcover film is the same as the exteriorly facing fire barrier laminate.7. The thermal acoustic insulation system of claim 5, wherein theinteriorly facing inboard cover film consists essentially of a polymerfilm.
 8. The thermal acoustic insulation system of claim 5, wherein theexteriorly facing fire barrier laminate and the interiorly facinginboard cover film are sealed with an adhesive to partially orsubstantially totally envelop or encapsulate the at least one insulatinglayer.
 9. A thermal acoustic insulation system that passes the flamepropagation and burnthrough resistance test protocols of 14 C.F.R.§25.856(a) and (b), Appendix F, Parts VI and VII, comprising at leastone insulating layer disposed within a covering of: (i) an exteriorlyfacing fire barrier laminate comprising: (a) a first film layer; (b) asupport layer on top of the first film layer; (c) a non-fibrous firebarrier layer on top of the support layer, the non-fibrous fire barrierlayer comprising at least one inorganic platelet; and (d) a second filmlayer on top of the support layer; wherein the at least one inorganicplatelet comprises mica; and (ii) an interiorly facing inboard coverfilm.
 10. The thermal acoustic insulation system of claim 9, wherein theinteriorly facing inboard cover film is the same as the exteriorlyfacing fire barrier laminate.
 11. The thermal acoustic insulation systemof claim 9, wherein the interiorly facing inboard cover film consistsessentially of a polymer film.
 12. The thermal acoustic insulationsystem of claim 9, wherein the exteriorly facing fire barrier laminateand the interiorly facing inboard cover film are sealed with an adhesiveto partially or substantially totally envelop or encapsulate the atleast one insulating layer.
 13. The thermal acoustic insulation systemof claim 9, wherein the non-fibrous fire barrier layer comprises mica inan amount from about 20 to about 100 weight percent, based on the totalweight of the non-fibrous fire barrier layer.
 14. The thermal acousticinsulation system of claim 9, wherein the non-fibrous fire barrier layercomprises mica in an amount of about 100 weight percent, based on thetotal weight of the non-fibrous fire barrier layer.
 15. The thermalacoustic insulation system of claim 9, wherein the non-fibrous firebarrier layer comprises an adhesive in addition to the at least oneinorganic platelet.
 16. The thermal acoustic insulation system of claim15, wherein the adhesive is a pressure sensitive adhesive.
 17. Thethermal acoustic insulation system of claim 16, wherein the pressuresensitive adhesive is a silicone pressure sensitive adhesive.
 18. Thethermal acoustic insulation system of claim 9, wherein there is anadhesive layer between the non-fibrous fire barrier layer and the secondfilm layer.
 19. The thermal acoustic insulation system of claim 18,wherein the adhesive is a pressure sensitive adhesive.
 20. The thermalacoustic insulation system of claim 19, wherein the pressure sensitiveadhesive is a silicone pressure sensitive adhesive.